Injection electrical connector

ABSTRACT

A high-pressure connector for use with a cable accessory having an injection port with an opening into an interior chamber defined by one or more sidewalls. The connector includes a body portion and one or more fluid seals. The body portion has an inner fluid chamber, an outer surface, and an aperture. The inner fluid chamber is configured to allow a conductor of a cable to pass therethrough. The fluid seal(s) are positionable between the outer surface of the body portion and the one or more sidewalls to define an outer fluid chamber. The outer fluid chamber is positioned such that the opening of the injection port is positioned within the outer fluid chamber so that a fluid exiting the injection port through the opening enters the outer fluid chamber. The aperture connects the outer and inner fluid chambers and allows the fluid to flow therebetween.

CROSS REFERENCE TO RELATED APPLICATION(S)

This application claims the benefit of U.S. Provisional Application No.62/329,132, filed on Apr. 28, 2016, which is incorporated herein byreference in its entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention is directed generally to components used withmedium voltage electrical power cables and, more particularly, tocomponents used to inject a fluid into an interior of a cable.

Description of the Related Art

A known problem that occurs in power cables (e.g., medium voltage soliddielectric power cables in underground distribution networks) is theformation of concentrations of moisture, sometimes referred to as “watertrees,” in the insulation that surrounds the cable conductor (e.g.,twisted wire strands). This dielectric breakdown is generally attributedto a “treeing” phenomena (i.e., formation of oxidized polymer indendritic patterns within the insulation material that resemble trees),which leads to a progressive degradation of the cable's insulation.

Treatment fluids (e.g., phenylmethyldialkoxysilane,dimethyldialkoxysilane, tolylethylmethyldialkoxysilane,cyanobutylmethyldialkoxysilane, and the like) have been developed thatare injected into the interior of the cable, diffuse into theinsulation, and interact with the moisture in the micro-voids. Thisprocess is sometimes referred to as cable rejuvenation. To inject thetreatment fluid, an injection port must be installed that provides fluidcommunication with the interior of the cable. For example, U.S. Pat.Nos. 7,195,504 and 7,538,274 describe injection adapters suitable forSustained Pressure injection of rejuvenation treatment fluid into apower cable. Sustained Pressure Rejuvenation (“SPR”) differs fromearlier injection methods because the injection occurs at higherpressures, typically greater than 30 psi, and the pressure is sealedinside the cable, and sustained therein, when injection has beencompleted. Such SPR injection is generally performed on de-energizedcables. However, SPR injection may be used on energized cablesterminated at both ends by live-front terminators that allow physicalfluid access to the interior of the cable.

There are times when it is desirable to introduce a treatment fluid intoand withdraw a treatment fluid from an energized cable having at leastone dead-front termination (e.g., when rejuvenating a cable with adielectric enhancement fluid). This is typically done at dead-frontterminations implemented using dead front injection elbows, such asthose described by U.S. Pat. Nos. 4,946,393 and 6,332,785. But it canalso be done at single piece injection splices and modular injectionsplices, which each have an injection port. Cable accessories thatinclude an injection port are generally referred to hereinafter as“injection components.”

Unfortunately, currently available dead front injection components(e.g., dead front injection elbows and injection splices) used tointroduce a restorative fluid into a cable's interior suffer from atleast one or more of the following eight shortcomings.

First, because the treatment fluid comes into intimate contact with theentirety of the annular interior of the injection component, a portionof the treatment fluid is wasted. Injection components typically includea semi-conductive insert, a surrounding layer of insulation, and asemi-conductive exterior layer. Unfortunately, a significant wastedportion of the treatment fluid injected into the injection componentpermeates into the semi-conductive insert, the surrounding layer ofinsulation, and the semi-conductive exterior layer. Further, at leastsome of the wasted portion exits the injection component into thesurrounding environment, and represents a significant fluid loss.Depending upon cable geometry, fluid delivery method, injectionpressure, and operating temperature, this loss may range from about 5%to about 15% of the treatment fluid supplied to the injection component.Further, this loss could exceed 15%.

Second, the treatment fluid may cause subcomponents of the injectioncomponent to swell and exceed desired tolerances and/or fail. Forexample, the treatment fluid may cause ethylene propylene diene monomer(“EPDM”) rubber and ethylene propylene rubber (“EPR”), the most commonpolymers used in injection components, to swell in excess of 40%_(w) atcable operating temperatures above about 50° C. This is a larger factorwhen a soak period is utilized (e.g., in small cables) to providesufficient fluid to the interiors of the cables. An injection componentexperiencing such swelling will no longer meet industry standarddimensional requirements, such as those of IEEE 386™. Further, thetreatment fluid may cause silicone rubber (often used to construct cabletermination and splicing accessories) to swell in excess of 40%_(w) atambient temperatures of about 20° C. Swelling to these extents can leadto failure of the component.

Third, currently available injection components limit maximum injectionpressures to a level that is less than optimum for cable rejuvenation.Cable accessories (e.g., elbows and splices) that have been designed toaccommodate fluid injection rely on an interference fit between thecable accessory and the cable insulation to retain fluid pressure.Generally this interface cannot contain pressures in excess of 30 psi.On the other hand, testing has shown that cable insulation can withstandpressures up to 1000 psi (dependent on configuration and insulationmaterial) and that using higher pressures improves the quality of thetreatment. Bertini & Keitges, “Silicone Injection: Better withPressure,” ICC, Sub. A., May 19, 2009.

Fourth, externally applied conventional hose clamps that compromise theelectrical integrity of the injection component are required to operatethe injection component at higher pressures. Currently utilizedinjectable components can withstand a maximum internal pressure within arange of about 5 psig to about 30 psig depending upon the size of thecable, the design of the injection component, operating temperature, andthe materials used to construct the injection component. Often, tooperate at the higher end of this range, an external hose clamp isapplied to the injection component to counteract hoop stress caused bythe fluid pressure. Unfortunately, the hose clamp deforms the injectioncomponent and compromises the electrical integrity of the injectioncomponent. Additionally, the hose clamps are typically left in place,and creep over time, which further compromises the electrical integrityof the injection component. While these hose clamps may be removed afterthe treatment is completed, doing so requires an additional visit to thecable termination, which increases both expense and risk of injury.

Fifth, a portion of the treatment fluid may leak from the branch of atreatment elbow that houses the probe pin. Injection elbows are the mostcommon dead-front components used to inject treatment fluid into acable. An O-ring or D-ring seal is conventionally applied to the base ofthe probe pin to prevent fluid from leaking out of the branch of theelbow housing the probe pin and into the environment or a mated bushing.Unfortunately, this seal has been known to leak, causing damage tobushings, and creating a fire or explosion hazard. This problem isdescribed in Bertini & Brinton, “A Comparison of Rejuvenation Hazards,”EDIST 2009, Jan. 13, 2009, which is incorporated herein by reference inits entirety.

Sixth, whenever the injection port is open (e.g., an injection cap or apermanent cap has been removed) some of the treatment fluid may flow outthrough the open injection port. This decreases residual pressure in thecable and (proportionally) the volume of the treatment fluid in thecable. Treatment fluid may spray or dribble from the injection port andcreate a hazard potential for fire, injure personnel, and/or contaminatethe environment.

Seventh, the permanent cap used to close the injection port of sometypes of injection components may be mistaken for a cap used to sealother types of devices found on cable accessories that are not used toinject treatment fluid into cables. For example, many permanent capshave an external ring-shaped attachment point that is used to remove andinstall the cap. This ring-shaped attachment point may be mistaken forthe external ring-shaped attachment point of a cap used on other devicesmounted on cable accessories. For example, the external ring-shapedattachment point of the permanent cap may be mistaken for an eye (oreyelet) included on an elbow and used to pull on the elbow. By way ofanother example, the external ring-shaped attachment point of thepermanent cap may be mistaken for a similar structure on a cover used toclose a capacitive test point that can easily be removed by a standardhot stick implement. Such mistakes can result in the permanent cap beingremoved from the injection port, which exposes the cable conductordirectly to atmosphere, creates a passage through which foreign objectscan come in contact with the voltage of the cable conductor, and apassage through which potential can spontaneously and violentlyflash-over creating an arc flash and a power outage. The temperature ofan arc flash can reach 35,000° F. and hence poses a substantial threatto operators and nearby equipment. Personnel unfamiliar with thefunction of the injection port can expose themselves to danger, create ahazard for others, and initiate a failure point if the permanent cap isnot promptly replaced and/or is handled improperly.

Therefore, a need exists for new injection components that avoid one ormore of the shortcomings discussed above. The present applicationprovides these and other advantages as will be apparent from thefollowing detailed description and accompanying figures.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1A is a perspective view of an embodiment of a modular injectioncomponent (“MIC”) connected to both a cable and a cable accessory(illustrated in cross-section).

FIG. 1B is a top view of the MIC of FIG. 1A connected to the cable and afitting of the cable accessory.

FIG. 2 is a perspective view of an end of the cable.

FIG. 3 is a longitudinal cross-sectional side view of the MIC of FIG.1A, which includes an injection port, an optional reticulated flashprevention (“RFP”) plug, an optional limited permeation insert (“LPI”),a MIC body, an optional valved injection adapter (“VIA”) assembly, and aMIC conductor.

FIG. 4 is a side view of the optional RFP plug.

FIG. 5 is a longitudinal cross-sectional side view of the MIC body ofthe MIC of FIG. 1A.

FIG. 6A is an enlargement of a portion of FIG. 3 omitting the optionalRFP plug.

FIG. 6B is an enlargement of a portion of FIG. 6A.

FIG. 7 is a perspective view of a subassembly including the cable, theoptional VIA assembly, and the MIC conductor.

FIG. 8 is a perspective view of the MIC conductor.

FIG. 9 is a perspective view of a VIA body of the optional VIA assembly.

FIG. 10 is a longitudinal cross-sectional side view of the VIA body.

FIG. 11A is a partially exploded perspective view of the optional VIAassembly, which includes the VIA body, VIA seals, a first embodiment ofa biasing member, an optional clip, and a valve cartridge.

FIG. 11B is a perspective view of a second embodiment of the biasingmember of the optional VIA assembly.

FIG. 12A is a lateral cross-sectional view of the optional VIA assemblyin which a poppet member of the valve cartridge is depicted in a closedposition.

FIG. 12B is a lateral cross-sectional view of the optional VIA assemblyin which the poppet member of the valve cartridge is depicted in an openposition.

FIG. 13 is a lateral cross-sectional view of the MIC of FIG. 1A with aninjection probe pin inserted into the injection port of the MIC andpressing upon the biasing member, which moves the poppet member to theposition depicted in FIG. 12B.

FIG. 14 is an exploded perspective view of the valve cartridge of theoptional VIA assembly.

FIG. 15 is a cross-sectional side view of a valve body of the valvecartridge.

FIG. 16 is a side perspective view of a poppet member of the valvecartridge.

FIG. 17 is a top view of the poppet member of FIG. 16.

FIG. 18 is a longitudinal cross-sectional side view of an alternateembodiment of the MIC that omits both the optional VIA assembly and theoptional LPI.

FIG. 19 is a longitudinal cross-sectional side view of a slice assemblyincluding an alternate embodiment of the LPI.

FIG. 20 is a flow diagram of a method of installing the MIC of FIG. 1Abetween the cable and the cable accessory.

FIG. 21 is a side view of an injection probe assembly being insertedinto the injection port of the MIC of FIG. 1A.

FIG. 22 is an exploded perspective view of the injection probe assembly.

FIG. 23A is a lateral cross-sectional view of the injection probeassembly coupled to the injection port of the MIC of FIG. 1A.

FIG. 23B is an enlargement of a portion of FIG. 23A.

FIG. 24A is a longitudinal cross-sectional side view of the injectionprobe assembly injecting a treatment fluid into the injection port ofthe MIC of FIG. 1A while both components are submerged in water withbold lines illustrating locations at which the water tries to infiltratethe injection probe assembly and the MIC.

FIG. 24B is a longitudinal cross-sectional side view of the injectionprobe assembly injecting the treatment fluid into the injection port ofthe MIC of FIG. 1A while both components are submerged in water withbold lines illustrating locations at which the treatment fluid tries toescape from the injection probe assembly and the MIC.

FIG. 25 is a perspective top view of a tapered injection nozzle of theinjection probe assembly.

FIG. 26 is a cross-sectional side view of an outer cap of the injectionprobe assembly.

FIG. 27 is a perspective view of an elbow shaped connector of theinjection probe assembly.

FIG. 28 is a perspective side view of a cap being inserted into theinjection port of the MIC of FIG. 1A.

FIG. 29 is a side view of the cap installed on the injection port of theMIC of FIG. 1A.

FIG. 30 is a lateral cross-sectional view of the cap installed on theinjection port of the MIC of FIG. 1A.

FIG. 31 is a perspective sectional view of the cap.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1A is a perspective view of an embodiment of a modular injectioncomponent (“MIC”) 100. The MIC 100 is used to connect a cable 110 to acable accessory 112 to form an assembly 114. As is apparent to those ofordinary skill in the art, the cable accessory 112 may be connected toother electrical equipment (not shown), such as a transformer, switch,feed-through bushing, etc.

In alternate embodiments (not shown), the cable accessory 112 may beintegrated into the MIC 100 or may be a subcomponent of the MIC 100. Insuch embodiments, the assembly 114 includes the MIC 100 and the cable110.

The MIC 100 includes an access or injection port 116 through whichtreatment fluid 120 may be inserted into (or withdrawn from) an interior122 (see FIG. 2) of the cable 110 by an injection probe assembly (e.g.,an injection probe assembly 130) or other injection device. For ease ofillustration, in FIG. 1A, the injection probe assembly has beenimplemented as the injection probe assembly 130. However, this is not arequirement and other types of injection probe assemblies or other typesof injection devices may be used with the MIC 100. For example, acap-like injection device configured to be removably coupled to theinjection port 116 may be used to inject the treatment fluid 120 intothe injection port 116. Such a device may include a friction fit plug orsimple cap that attaches to the injection port 116 but does not extendinwardly into the injection port 116. Alternatively, the cap-likeinjection device may be held into place on the injection port 116 by afastener (e.g., a hook or strap) that attaches to or wraps around theMIC 100. By way of another non-limiting example, the injection devicemay have a nozzle that is inserted into the injection port 116 and heldin place by a human operator as the injection occurs.

One of ordinary skill in the art of cable rejuvenation readilyrecognizes that while nominally pure treatment fluids are introducedinto a first cable end, what comes out the second end is not preciselythe same as the introduced treatment fluid. The treatment fluid willpick up contaminants, including, but not limited to, carbon black, clayfillers, organic compounds, water, and ions. In fact, at the fluidoutlet, water and ions may be pushed ahead of the injected treatmentfluid. The effluent cannot be known a priori and must be assumed to beconductive for safety reasons. These contaminants disrupt the dielectricproperties of the treatment fluid as introduced and create electricalcontainment issues when a cable is treated while energized. These issuesare most severe at the fluid outlet, but even the inlet may becontaminated by Brownian diffusion where inlet flow rates are very low.Therefore, after introduction into the cable, treatment fluid isunderstood to include nominally pure treatment fluid, contaminatedtreatment fluid, and any fluid (e.g., water with ions) existing in thecable interior prior to injection that is pushed ahead of the treatmentfluid.

In the embodiment illustrated, the injection probe assembly 130 isconnected by a hose or tube 132 to a fluid source 134 (e.g., a tank), inwhich the treatment fluid 120 is stored. The injection probe assembly130 has an injection probe pin 136 configured to extend into theinjection port 116 when the injection probe assembly 130 is attached tothe injection port 116.

Inside the fluid source 134, a pressurized gas 135 applies pressure tothe treatment fluid 120. Thus, the treatment fluid 120 is under pressureinside the fluid source 134. The pressurized gas 135 may be supplied tothe fluid source 134 by an external tank (not shown). The fluid source134 may include a gauge (not shown) that may be used to display thepressure inside the fluid source 134. Alternate means, such as but notlimited to a pump (not shown) may be used to supply the treatment fluid120 under pressure. The treatment fluid 120 may be implemented using anycable treatment or rejuvenation fluid known in the art. Non-limitingexamples of such fluids include phenylmethyldialkoxysilane,dimethyldialkoxysilane, tolylethylmethyldialkoxysilane,cyanobutylmethyldialkoxysilane and the like.

Alternatively, the injection probe assembly 130 (other injection device)could be used to pump dry air or gas into the interior 122 of the cable110 through the injection port 116 of the MIC 100.

A cap 140 may be used to close the injection port 116 and seal it fromthe outside environment whenever the injection probe assembly 130 (orother injection device) is not connected to the injection port 116. Thecap 140 has a stem portion 142 configured to extend into the injectionport 116 when the cap 140 is attached to the injection port 116, whichprevents fluid from exiting the MIC 100 through the injection port 116and (as explained below) insulates the interior of the MIC 100 from theoutside environment. The stem portion 142 is constructed fromelectrically insulating material. The cap 140 also has a skirt portion144 that is spaced apart from and surrounds the stem portion 142. Theskirt portion 144 is constructed from electrically semi-conductivematerial. The skirt portion 144 receives the injection port 116 andextends along its outer surface when the cap 140 is attached to theinjection port 116 with the stem portion 142 inserted therein.

The cap 140 may be characterized as being permanent because the cap 140closes the injection port 116 electrically. As explained below, the stemportion 142 extends into the injection port 116 to complete theinsulation. At the same time, the skirt portion 144 extends along theoutside of the injection port 116 and (as explained below) mates with asemi-conductive outer insulation shield 332 (see FIGS. 3 and 5) of anouter housing or MIC body 310 (which may be connected to ground by aground wire) of the MIC 100. Thus, the cap 140 may be used to seal theMIC 100 in a manner that makes the sealed MIC 100 operate as a fullydead-front device.

Referring to FIG. 2, the cable 110 extends longitudinally along a cableaxis 200. For ease of illustration, in FIG. 2, the cable 110 isillustrated as a conventional jacketed concentric neutral UndergroundResidential Distribution (“URD”) cable used for medium voltageapplications. However, the cable 110 may be implemented usingalternative cables such as a non-jacketed bare concentric neutral URDcable, a cable with one or more tape shields, a low voltage cable, andthe like.

The cable 110 includes a longitudinally extending cable conductor 202(e.g., including a plurality of longitudinally extending electricallyconductive strands 203) surrounded lengthwise by a plurality ofconcentrically oriented layers 204. Interstitial spaces 205 between theconductive strands 203 provide one or more flow paths through theinterior 122 of the cable 110. In the embodiment illustrated, the layers204 include a conductor shield 206 immediately adjacent the cableconductor 202, a substantially non-conductive insulation layer 208immediately adjacent the conductor shield 206, and a semi-conductiveinsulation shield 210 immediately adjacent the insulation layer 208. Aplurality of concentric wires or neutrals 212 may be wound around theinsulation shield 210. The outermost of the layers 204 is a cable jacket214 that covers and protects the other layers of the cable 110.

Referring to FIG. 3, the cable 110 is connected at its end 220 to theMIC 100. Before the cable 110 is connected to the MIC 100, at the end220, portions of the cable jacket 214 (see FIG. 2) and the neutrals 212(see FIG. 2) are removed to expose an end portion 222 of the insulationshield 210. Then, an end most portion of the exposed end portion 222 ofthe insulation shield 210 is removed to expose an end portion 223 of theinsulation layer 208. Finally, a portion of the exposed end portion 223of the insulation layer 208 and the conductor shield 206 (see FIG. 2)underneath the exposed end portion 223 are removed to expose an endportion 224 of the cable conductor 202. The cable conductor 202 has anouter diameter 226 (see FIG. 2).

Referring to FIG. 1A, the MIC 100 may be used to inject the treatmentfluid 120 into the cable 110 when the cable is energized. In suchimplementations, the cable accessory 112 may be implemented as astandard dead-front cable accessory. For ease of illustration, in FIG.1A, the cable accessory 112 is illustrated as a conventional dead-frontload break elbow. However, the cable accessory 112 may be implementedusing alternative cable accessories such as a splice, another MIC (likethe MIC 100), a dead-break elbow, a non-load-break elbow, a separableconnector, a stress-control termination, a live-front termination, andthe like.

The cable accessory 112 includes a fitting 230 configured to beconnected to the cable conductor 202 (see FIG. 2) and form an electricalconnection therewith. By way of non-limiting examples, the fitting 230may be a coppertop connector. In the embodiment illustrated, the fitting230 has a compression connector 232 and a threaded hole 235 (see FIG.1B). In the embodiment illustrated, the cable accessory 112 includes acontact probe 236 (also referred to as a probe pin) that is removablyconnectable to the fitting 230 via the threaded hole 235 (see FIG. 1B).The contact probe 236 has a threaded end 237 configured to be threadedinto the threaded hole 235 (see FIG. 1B) of the fitting 230.

The cable accessory 112 has an outer housing 240 configured to house thefitting 230 therein. In the embodiment illustrated, the outer housing240 includes a semi-conductive outer insulation shield 241. The housing240 has an opening 242 formed in the semi-conductive outer insulationshield 241 into which the fitting 230 may be inserted during assembly ofthe cable accessory 112. When the cable accessory 112 is implemented asan elbow, the housing 240 has an internal L-shaped channel 246 with afirst branch 248 that opens at the opening 242, and a second branch 250that opens at an opening 252. The contact probe 236 may be inserted intothe housing 240 through the opening 252 and connected to the fitting 230at or near the intersection of the first and second branches 248 and250. Then, an elbow bushing 256 may be inserted into the housing 240through the opening 252 and connected to the contact probe 236. Theelbow bushing 256 sealingly mates with the housing 240 within the secondbranch 250 and along the opening 252.

Optionally, the outer housing 240 may include a port 254 formed thereinthat is closed by a removable cap 257. The cap 257 includes an externalring-shaped attachment point or pulling eyelet 258. By way of anon-limiting example, the port 254 may be a capacitive test point andthe cap 257 may be removed by a standard hot stick implement.Optionally, the outer housing 240 may include a pulling eyelet 260 thatmay be used to pull on the cable accessory 112 (e.g., using a standardhot stick implement).

The MIC 100 has a first end portion 300 opposite a second end portion302. The first end portion 300 is connectable to the end 220 of thecable 110 and the second end portion 302 of the MIC 100 is connectableto the cable accessory 112. The first end portion 300 forms a mechanicalconnection with the cable 110 that helps prevent movement of the cable110 relative to the MIC 100. As will be described in more detail below,the first end portion 300 also provides an electrical connection withthe cable conductor 202 (see FIG. 2), and forms both an electricallyinsulated connection, and a fluid tight seal with the cable 110.Similarly, the second end portion 302 forms a mechanical connection withthe fitting 230 of the cable accessory 112 that helps prevent movementof the MIC 100 (and the cable 110) relative to the cable accessory 112.As will be described in more detail below, the second end portion 302also provides an electrical connection with the fitting 230 of the cableaccessory 112, and forms both an electrically insulated connection, anda fluid tight seal with the cable accessory 112. The fluid tight sealsformed by the first and second end portions 300 and 302 may beconfigured to withstand injection pressures of about 5 psi to about 30psi. However, as described below, the MIC 100 may be configured for usewith higher injection pressures.

The MIC 100 may be used to inject the treatment fluid 120 into a widevariety of cable types and sizes (e.g., different conductor diameters,different insulation thicknesses, and the like). For example, the MIC100 may be configured for use with the following:

-   -   1. cables and/or cable accessories used for different voltage        classes (e.g., secondary voltages below 600v, medium voltage        cables including 15 kV, 25 kV, and 35 kV, and transmission        voltage above 35 kV);    -   2. cable accessories having small or large bushing interfaces        used at 35 kV;    -   3. cable accessories that include dead-break and load-break        components;    -   4. cable accessories with and without capacitive test points;        and    -   5. cables and/or cable accessories having different lengths        (e.g., standard, elongated, and repair lengths).

Referring to FIG. 3, the MIC 100 includes the MIC body 310, an optionallimited permeation insert (“LPI”) 312, an optional reticulated flashprevention (“RFP”) plug 314, a MIC conductor 318, and an optional valvedinjection adapter (“VIA”) assembly 320. Referring to FIG. 7, the MICconductor 318, the VIA assembly 320, and the cable 110 may be assembledtogether into a subassembly 330 that is inserted into the MIC body 310(see FIGS. 1A, 3, and 5) as described below.

MIC Body

As mentioned above, the LPI 312 and the VIA assembly 320 are bothoptional. FIGS. 1A, 3, 5-6B, 13, 21, 23A, 24A, and 24B depict anembodiment of the MIC body 310 configured for use with the LPI 312 andthe VIA assembly 320. FIG. 18 depicts an embodiment of a MIC body 310′that may be used to construct an embodiment of the MIC 100 that omitsboth the LPI 312 and the VIA assembly 320.

Referring to FIG. 5, in the embodiment illustrated, the MIC body 310 isconstructed (e.g., molded) as a single unit. However, in alternateembodiments (not shown), the MIC body 310 may be constructed from two ormore body components assembled together. In the embodiment illustrated,the MIC body 310 includes the semi-conductive outer insulation shield332, an insulation portion 334, and a semi-conductive layer or insert336. The outer insulation shield 332 provides a semi-conductive exteriorthat may be connected to ground (e.g., by a ground wire) and act as aground plane. The outer insulation shield 332 and the insert 336 may beformed first, placed in a mold, and the insulation portion 334 injectedinto the mold to connect the outer insulation shield 332 and the insert336 together. The MIC body 310 may be molded around the LPI 312 orotherwise constructed therewith as a unit. For example, the optional LPI312 may be placed in the mold with the outer insulation shield 332 andthe insert 336 before the insulation portion 334 is injected into themold. By way of a non-limiting example, the MIC body 310 may beconstructed from EPDM rubber, EPR, silicone rubber, one or more othercompliant insulating materials, and the like.

The MIC body 310 extends longitudinally along a MIC axis 340 and has afirst end 350 opposite a second end 352. The first end 350 is formed inthe outer insulation shield 332. The second end 352 is formed in boththe insulation portion 334, and the insert 336. The first end 350 has analignment feature 338 (e.g., a raised portion) that (as described below)may be used to align the subassembly 330 (see FIG. 7) with the injectionport 116. Referring to FIG. 3, at the first end 350, the outerinsulation shield 332 mates with the semi-conductive insulation shield210 of the cable 110 to continue a dead-front ground plane across theconnection therebetween. The dead-front ground plane is also continuedacross the connection formed between the second end 352 and the cableaccessory 112 (see FIG. 1A). Referring to FIG. 1A, the opening 242formed in the semi-conductive insulation shield 241 of the cableaccessory 112 mates with the outer insulation shield 332 (see FIG. 3) ofthe MIC body 310.

Referring to FIG. 5, an open ended internal channel 356 extends throughthe MIC body 310 along the MIC axis 340 from the first end 350 to thesecond end 352. As shown in FIG. 3, the internal channel 356 isconfigured to house the subassembly 330 (see FIG. 7) with the cable 110and the MIC conductor 318 extending outwardly from the MIC body 310. Thecable 110 extends outwardly from the internal channel 356 through afirst channel opening 360 formed in the first end 350 of the MIC body310. The MIC conductor 318 exits from the internal channel 356 through asecond channel opening 362 formed in the second end 352 of the MIC body310.

Referring to FIG. 5, the internal channel 356 passes through an interiorchamber 366 defined in the insert 336 of the MIC body 310. The injectionport 116 has an outer sidewall 368 formed in the insulation portion 334of the MIC body 310 at a location between the first and second ends 350and 352. Along its base, the outer sidewall 368 is surrounded by theouter insulation shield 332. The injection port 116 is in fluidcommunication with the interior chamber 366. The injection port 116 hasan outer opening 370 connected to an inner opening 372 by a taperedchannel 376. An outer portion of the tapered channel 376 is defined bythe outer sidewall 368, and an innermost portion of the tapered channel376 is defined by the insert 336. The tapered channel 376 narrows towardthe inner opening 372, which opens into the interior chamber 366. In theembodiment illustrated, the tapered channel 376 stops narrowing at ornear the interface between the insulation portion 334 and the insert336. Referring to FIG. 3, the interior chamber 366 is configured tohouse the VIA assembly 320 with the VIA assembly 320 positioned adjacentthe inner opening 372 (see FIG. 5) of the injection port 116.

Referring to FIG. 5, optionally, at least one projection 378 may bepositioned between the injection port 116 and the first end 350. Theprojection 378 extends inwardly into the interior chamber 366 and isconfigured to engage the VIA assembly 320 (see FIG. 3) and help maintainthe VIA assembly 320 in a desired longitudinal position within the MICbody 310.

Optionally, at least one recess 379 may be positioned between theinjection port 116 and the first end 350. The recess 379 extendsoutwardly away from the interior chamber 366. In the embodimentillustrated, the optional recess 379 is immediately adjacent theoptional projection 378. The optional recess 379 is configured to engagethe subassembly 330 (see FIG. 3) and help maintain the subassembly 330in a desired longitudinal position within the MIC body 310.

In the embodiment illustrated, the tapered channel 376 is substantiallyorthogonal to the internal channel 356 (which extends along the MIC axis340). The MIC body 310 may be rotated about the MIC axis 340 when thesubassembly 330 (see FIG. 7) is positioned inside the internal channel356 to position the injection port 116 for convenient access and avoidinterference with other structures (e.g., a switching cabinet, atransformer, other devices in a switching cabinet, and the like). Thus,clearance problems experienced with prior art elbow injection adaptorsmay be avoided. Additionally, the stack height may be reduced by anglingthe injection port 116 away from the elbow bushing 256, which isperpendicular to the cabinet door. Referring to FIG. 1A, although theinjection port 116 of the MIC 100 is illustrated as being oriented inthe same plane as the second branch 250 (and the contact probe 236) ofthe cable accessory 112, the injection port 116 (and hence the MIC body310) could be rotated (or radially displaced) about the MIC axis 340(see FIG. 5) by up to 180 degrees to allow a better fit within aconfined interior space (e.g., within a switching cabinet or otherstructure).

Referring to FIG. 18, the MIC body 310′ may be constructed using anymethods and materials suitable for constructing the MIC body 310 (seeFIGS. 1A, 3, 5-6B, 13, 21, 23A, 24A, and 24B). Like the MIC body 310,the MIC body 310′ includes a semi-conductive outer insulation shield332′, an insulation portion 334′, and a semi-conductive layer or insert336′. The outer insulation shield 332′ may be connected to ground (e.g.,by a ground wire) and act as a ground plane. The MIC body 310′ has afirst end 350′ opposite a second end (not shown) that are substantiallyidentical to the first and second ends 350 and 352, respectively, of theMIC body 310.

An open ended internal channel 356′ extends through the MIC body 310′from the first end 350′ to the second end (not shown). The internalchannel 356′ is configured to house portions of the cable 110 and theMIC conductor 318. The internal channel 356′ passes through an interiorchamber 366′ defined in the insert 336′ of the MIC body 310′. Theexposed end portion 224 of the cable conductor 202 is coupled to the MICconductor 318 inside the interior chamber 366′. The cable 110 extendsoutwardly from the interior chamber 366′ through the internal channel356′ in a first direction and the MIC conductor 318 extends outwardlyfrom the interior chamber 366′ through the internal channel 356′ in asecond direction that is opposite the first direction.

The injection port 116 has an outer sidewall 368′ formed in theinsulation portion 334′ of the MIC body 310′. Along its base, the outersidewall 368′ is surrounded by the outer insulation shield 332′. Theinjection port 116 is in fluid communication with the interior chamber366′. The injection port 116 has an outer opening 370′ connected to aninner opening 372′ by a tapered channel 376′. An outer portion of thetapered channel 376′ is defined by the outer sidewall 368′, and aninnermost portion of the tapered channel 376′ is defined by the insert336′. The tapered channel 376′ narrows toward the inner opening 372′,which opens into the interior chamber 366′.

In the embodiment illustrated, the tapered channel 376′ is substantiallyorthogonal to the internal channel 356′. The MIC body 310′ may berotated about the cable axis 200 (see FIG. 2) to position the injectionport 116 in a desired location with respect to other external structures(e.g., a switching cabinet, a transformer, other devices in a switchingcabinet, and the like) when the cable 110 and the MIC conductor 318 arecoupled together inside the internal channel 356′.

The insert 336′ seals against the MIC conductor 318, and the insulationportion 334′ seals against insulation layer 208 of the cable 110. Theseseals prevent the treatment fluid 120 (see FIG. 1A) leaking out of theopen ends of the internal channel 356′. An optional exterior compressionband or clamp 377 may be installed on the MIC body 310′ between theinjection port 116 and the first end 350′ to compress the MIC body 310′against the cable 110 and help seal the insulation portion 334′ againstthe insulation layer 208 of the cable 110.

Optional LPI

FIGS. 6A and 6B are enlarged partial cross-sections of the MIC 100 andomit the optional RFP plug 314 (see FIGS. 3 and 4). Referring to FIG.6A, the optional LPI 312 may be characterized as being an inner body ora liner that lines (and optionally reinforces) the tapered channel 376of the injection port 116 and a portion 380 of the interior chamber 366(defined in the insert 336 of the MIC body 310) adjacent the inneropening 372 of the tapered channel 376. In the embodiment illustrated,an exterior portion 400 of the LPI 312 extends outwardly beyond thetapered channel 376 through the outer opening 370. The exterior portion400 may include a lip or flange 402 configured to be positioned againstand cover the outermost portion of the injection port 116 adjacent theouter opening 370. The exterior portion 400 may include one or moreconnectors 404A and 404B spaced outwardly from the flange 402 andconfigured to be removably coupled to the injection probe assembly 130(see FIG. 1A) or the cap 140 (see FIG. 1A). In the embodimentillustrated, the connectors 404A and 404B have been implemented as apair of projections of a bayonet type connector.

The LPI 312 has an outer opening 410 formed in the exterior portion 400,and an inner opening 412 that opens into the interior chamber 366. Atapered first through channel 416 extends inwardly from the outeropening 410 to the inner opening 412 within the portion of the LPI 312lining the injection port 116. By way of a non-limiting example, thetapered first through channel 416 may taper along its length at least 3degrees or at least 15 degrees. By way of another non-limiting example,the tapered first through channel 416 may taper along its length byabout 0.5 degrees to about 30 degrees. An internal shoulder 418 may beformed in the LPI 312 near the inner opening 412. Referring to FIG. 3,when present, the RFP plug 314 may be inserted into the first throughchannel 416 and may rest upon the shoulder 418 (see FIGS. 6A and 6B).Referring to FIG. 6B, a portion of the first through channel 416 betweenthe shoulder 418 and the inner opening 412 may be too narrow to allowthe RFP plug 314 (see FIGS. 3 and 4) to pass therethrough.

A second through channel 426 extends along the MIC axis 340 (see FIG. 5)through the LPI 312 within the lined portion 380 of the interior chamber366. The second through channel 426 is configured to house at least aportion of the VIA assembly 320. The second through channel 426 may besubstantially orthogonal to the first through channel 416.

The LPI 312 may be characterized as having the first portion that linesthe injection port 116 and a second portion that lines the lined portion380 of the interior chamber 366. The first portion includes the taperedfirst through channel 416 and the second portion includes the secondthrough channel 426. While in the embodiment illustrated, the first andsecond portions are part of the unitary LPI 312, in alternateembodiments, the first and second portions may be separate components.Optionally, in such embodiments, the first and second portions may becoupled together to form a continuous LPI. Alternatively, the first andsecond portions may be spaced apart and define a discontinuous LPI.

In the embodiment illustrated, the optional recess 379 (see FIG. 5)formed in the MIC body 310 is positioned along an edge 428 of the LPI312 that is positioned between the injection port 116 and the first end350 of the MIC body 310. Alternatively, the optional recess 379 may beomitted and the edge 428 may function as lip or stop within the interiorchamber 366 of the MIC body 310.

The LPI 312 is constructed from a material that limits or restrictspermeation of the treatment fluid 120 (see FIG. 1A) therethrough. Whenpresent, the LPI 312 prevents the treatment fluid 120 (see FIG. 1A) fromquickly permeating into and through the material used to construct theMIC body 310 or portions thereof. In other words, the LPI 312 limitsunrestricted permeation of the treatment fluid 120 into the MIC body310. Because the treatment fluid 120 may degrade the physical and/orelectrical properties of the MIC body 310, the LPI 312 may help increasethe useful life of the MIC 100 (or other cable accessory into which theLPI 312 has been incorporated). The LPI 312 also reduces the amount ofthe treatment fluid 120 that is lost or wasted by permeation of thetreatment fluid 120 into structures (e.g., the MIC body 310) outside thecable 110, which assures that more of the treatment fluid 120 isavailable to treat the cable 110.

The LPI 312 may provide an inherently better seal with respect to theinsulation layer 208 that helps keep the treatment fluid 120 confined soit cannot leak out between the MIC 100 and the cable 110. Similarly, theLPI 312 may help provide an inherently better seal with respect to thecable accessory 112 (see FIG. 1A) that helps keep the treatment fluid120 confined so it cannot leak out between the MIC 100 and the cableaccessory 112. These fluid tight seals allow the MIC 100 to be operatedat higher pressures than conventional injection components. For example,the LPI 312 may be configured such that the MIC 100 is able to withstandinjection pressures of about 30 psi to about 1000 psi. By way of anothernon-limiting example, the LPI 312 may be used to provide sustainedpressure rejuvenation (“SPR”) processes, such as those described in U.S.Pat. Nos. 7,611,748, 8,205,326, 8,656,586, and 7,976,747.

As mentioned above, the LPI 312 is constructed from a material thatlimits or restricts permeation of the treatment fluid 120 (see FIG. 1A)therethrough. For example, the material may have a low solubility (e.g.,less than 5%_(w) at 90° C., less than 1° %_(w) at 90° C., or less than0.1° %_(w) at 90° C.) in the treatment fluid 120 and/or the material andthe treatment fluid 120 may have a small diffusion coefficient (e.g.,less than 10⁻⁷ cm²/s at 90° C., less than 10⁻⁸ cm²/s at 90° C., or lessthan 10⁻⁹ cm²/s at 90° C.). Low solubility, small diffusion coefficient,and the product of the solubility and diffusion are determined relativeto the same properties in the material used to construct the MIC body310 (e.g., EPDM rubber). For example, the material used to construct theLPI 312 is less soluble (e.g., five times, 20 times, or 100 times lesssoluble) than the material used to construct the MIC body 310 (e.g.,EPDM rubber) and the material may have a smaller diffusion coefficientwith the treatment fluid 120 and therefore slower diffusion (ten times,100 times, or 1000 times slower diffusion) than the material used toconstruct the MIC body 310 (e.g., EPDM rubber). For example, thetreatment fluid 120 may diffuse through the LPI 312 at a first rate thatis slower than a second rate at which the treatment fluid 120 diffusesthrough the MIC body 310. The first rate may be be slower than thesecond rate by at least about 10 times, at least about 100 times, or atleast about 1000 times. By way of another non-limiting example, the MICbody 310 may have a first solubility in the treatment fluid 120 and theLPI 312 may have a second solubility in the treatment fluid 120. Thefirst solubility may be at least about five times, at least about 20times, or at least about 100 times greater than the second solubility.

Non-limiting examples of low permeability materials that may be used toconstruct the LPI 312 include dense plastics such as nylon,polyethylene, polypropylene, polyoxymethylene (also known as acetal,polyacetal, and polyformaldehyde), polytetrafluoroethylene (“PTFE”),other fluoropolymers, and the like, which are chemically compatible withthe treatment fluid 120. The low permeability material might alsoinclude an elastomer, such as Viton® or a similar fluorinated elastomer.The LPI 312 may also be made of an essentially non-permeable material,such as metal, glass, ceramic, and the like. By way of anothernon-limiting example, the LPI 312 may be constructed from fiber glassfilled (or reinforced) nylon.

When the LPI 312 is constructed using one or more hard materials, suchas plastic, metal, glass, and the like, the LPI 312 can withstandconsiderably greater hoop forces (e.g., than EPDM rubber) and can beemployed to make seals capable of sealing against higher pressures(e.g., than EPDM rubber). By way of a non-limiting example, the portionof the LPI 312 that lines the portion 380 of the interior chamber 366may be constructed from a first material (e.g., metal) and the portionof the LPI 312 that lines the tapered channel 376 of the injection port116 may be constructed from a different material.

While described as being integrated into the MIC 100, the LPI 312 may beincluded in (e.g., molded or inserted into) other types of cableaccessories with or without direct access ports or injection ports. Byway of non-limiting examples, the LPI 312 may be included in a splice, adead-break elbow, a load-break elbow, a non-load-break elbow, aseparable connector, a stress-control termination, a live-fronttermination, and the like.

FIG. 19 is a view of a longitudinal cross-section of a splice assembly430 including an outer body 431, a LPI 432, an electrically conductiveconnector 433, and optional seals 434A and 434B. The outer body 431 maybe constructed using any materials suitable for constructing the MICbody 310. By way of a non-limiting example, the outer body 431 may beimplemented using a cold shrink sleeve (not shown). The outer body 431has a through-channel 435 that passes through an interior chamber 436.

The LPI 432 may be constructed using any materials suitable forconstructing the LPI 312. The LPI 432 lines the interior chamber 436.The optional seals 434A and 434B may be positioned inside optionalcircumferential grooves G1 and G2 formed on an inwardly facing wall ofthe LPI 432.

The splice assembly 430 is used to interconnect two cable sections C1and C2. Each of the cable sections C1 and C2 may be substantiallysimilar to the cable 110 (see FIG. 2) and may be implemented using anytype of cable suitable for implementing the cable 110. The cablesections C1 and C2 include cable conductors 202A and 202B, respectively,each like the cable conductor 202 (see FIG. 2). The cable sections C1and C2 may each include one or more layers, like the one or more of thelayers 204 (see FIG. 2) of the cable 110, that surround the cableconductors 202A and 202B. For example, the cable conductors 202A and202B may each be surrounded by a conductor shield (not shown) like theconductor shield 206 (see FIG. 2). The conductor shields (not shown) ofthe cable sections C1 and C2 may be surrounded by insulation layers 208Aand 208B, respectively, each like the insulation layer 208 (see FIG. 2).The insulation layers 208A and 208B may be surrounded by insulationshields 210A and 210B, respectively, each like the insulation shield 210(see FIG. 2). The insulation shields 210A and 210B may be surrounded byneutrals 212A and 212B, respectively, each like the neutrals 212 (seeFIG. 2). The neutrals 212A and 212B may be surrounded by cable jackets214A and 214B, respectively, each like the cable jacket 214 (see FIG.2).

The splice assembly 430 is assembled by first exposing ends E1 and E2 ofthe cable conductors 202A and 202B, respectively. The neutrals 212A andthe cable jacket 214A are also stripped back to expose an end portionPIS1 of the insulation shield 210A. Similarly, the neutrals 212B and thecable jacket 214B are stripped back to expose an end portion PIS2 of theinsulation shield 2106. The insulation shields 210A and 210B arestripped back to expose portions PIL1 and PIL2, respectively, of theinsulation layers 208A and 208B, respectively.

A selected one of the cable sections C1 and C2 is inserted into thethrough-channel 435 formed in the outer body 431. For ease ofillustration, the cable section C1 will be described as being insertedinto the through-channel 435. The outer body 431 is slid along the cablesection C1 away from the end E1 and spaced longitudinally far enoughaway from the end E1 to allow the electrically conductive connector 433to be attached to the end E1. Next, the exposed end E2 of the cableconductor 202B is also coupled to the electrically conductive connector433. The connector 433 may be implemented using a conventionalcompression type connector or other connection means known in the artused to connect two cable conductors together to form an electricalconnection therebetween.

After the exposed ends E1 and E2 have been coupled together by theconnector 433, the outer body 431 is slid along the cable section C1 andover the connector 433, which is positioned inside the interior chamber436. The cable section C1 extends outwardly from the interior chamber436 through the through-channel 435 in a first direction, and the cablesection C2 extends outwardly from the interior chamber 436 through thethrough-channel 435 in a second direction that is opposite the firstdirection.

In embodiments that include the optional seals 434A and 434B, the seals434A and 434B are sandwiched between the LPI 432 and the exposedportions PIL1 and PIL2, respectively, of the insulation layers 208A and208B, respectively. In this manner, the interior chamber 436 may besealed off from the outside environment. In embodiments that omit theoptional seals 434A and 434B, portions of the outer body 431 adjacentthe LPI 432 may press against the exposed portions PIL1 and PIL2,respectively, of the insulation layers 208A and 208B, and form sealstherewith.

In embodiments in which the outer body 431 is implemented using ashrink-to-fit sleeve (e.g. cold shrink sleeve or heat shrink sleeve; notshown), the LPI 432 and the cold shrink sleeve (not shown) are separatecomponents. The cable section C1 is inserted through both the LPI 432and the cold shrink sleeve (not shown) and the exposed end E1 of thecable section C1 is spaced longitudinally far enough away from the LPI432 and the cold shrink sleeve (not shown) to allow the electricallyconductive connector 433 to be attached thereto. After the exposed endsE1 and E2 have been coupled together by the connector 433, the LPI 432is slid along the cable section C1 and over the connector 433, which ispositioned inside the interior chamber 436. Then, the cold shrink sleeve(not shown) is slid over and shrunk onto the LPI 432. The cold shrinksleeve (not shown) extends outwardly from the LPI 432 and covers atleast a portion of each of the exposed portions PIL1 and PIL2.

Like the MIC body 310 (see FIGS. 3 and 5), the outer body 431 has asemi-conductive or high dielectric constant outer insulation shield 437,an insulation portion 438, and a semi-conductive or high dielectricconstant inner insulation shield 439. The outer insulation shield 437contacts and presses against the exposed portions PIS1 and PIS2,respectively, of the insulation shields 210A and 210B. The innerinsulation shield 439 lines the interior chamber 436. In the embodimentillustrated, the LPI 432 is adjacent and lines the inner insulationshield 439. The insulation portion 438 is between the outer and innerinsulation shields 437 and 439.

When the treatment fluid 120 (see FIG. 1A) is injected into one of thecable sections C1 and C2 (e.g., via the MIC 100 illustrated in FIG. 1A),the treatment fluid 120 will flow into the interior chamber 436. The LPI432 prevents the treatment fluid 120 (see FIG. 1A) from quicklydiffusing into and through the material used to construct the outer body431 or portions thereof. In other words, the LPI 432 limits unrestrictedpermeation of the treatment fluid 120 into the outer body 431. Thus, theLPI 432 may help increase the useful life of the splice assembly 430and/or reduce the amount of the treatment fluid 120 that is lost orwasted by permeation of the treatment fluid 120 into structures outsidethe cable sections C1 and C2. Further, because the LPI 432 may provide abetter seal with respect to the insulation layers 208A and 208B, higherpressures (than those used with conventional injection components) maybe used to inject the treatment fluid 120 into the cable sections C1 andC2. For example, the LPI 432 may be configured to withstand injectionpressures of about 30 psi to about 1000 psi. By way of anothernon-limiting example, the SPR processes (discussed above) may be appliedto the splice assembly 430.

Optional RFP Plug

Referring to FIG. 1A, as mentioned above, an injection probe assembly(e.g., the injection probe assembly 130) or other injection device maybe used to inject the treatment fluid 120 into the injection port 116.However, when the injection of the treatment fluid 120 is completed, theinjection probe assembly or other injection device is removed from theinjection port 116. When the cable 110 is energized, this exposes theenergized cable conductor 202 to the outside environment (via theunobstructed injection port 116) during a time interval that extendsfrom a time at which the injection probe assembly (or other injectiondevice) is removed until a time at which an insulating permanent cap(e.g., the cap 140) is inserted into the injection port 116 to seal it.Unfortunately, during this time interval, the voltage of the cableconductor 202 may ionize air, water, or other materials in the injectionport 116 and a flashover (or arc flash) may occur between the cableconductor 202 or the MIC conductor 318 and a ground plane (e.g., thenearby outer insulation shield 332 of the MIC body 310, the nearby outerinsulation shield 332′ of the MIC body 310′, and the like). Such an arcflash can damage the MIC 100 and/or other components connected to ornear the MIC 100 (e.g., a transformer or other equipment in theimmediate area) and presents a thermal and electrical danger for a humanoperator.

Referring to FIG. 3, the optional RFP plug 314 may be used to at leastpartially dielectrically block the injection port 116 and prevent thecable conductor 202 from being exposed to the outside environment (e.g.,via the tapered channel 376′ of the MIC body 310′ or the first throughchannel 416 of the MIC body 310). Referring to FIG. 3, in the embodimentillustrated, the RFP plug 314 has a generally cylindrical orfrustoconical outer shape with circular cross-sectional shape that fitssnuggly within the tapered channel 376′ (see FIG. 18) in embodimentsomitting the LPI 312 or within the first through channel 416 inembodiments that include the LPI 312.

Referring to FIG. 4, the RFP plug 314 includes a reticulated portion 450that may be adjacent an optional non-reticulated rigid layer 452 (e.g.,a washer or similar structure). The reticulated portion 450 is soft andcompliant enough to allow an injection probe (e.g., the injection probepin 136 illustrated in FIG. 1A) or a similar structure to passtherethrough when an injection probe assembly (e.g., the injection probeassembly 130) or other injection device is used to inject the treatmentfluid 120 (see FIG. 1A) into the cable 110. The injection probe may forma through-hole in the reticulated portion 450 as it passes through.However, this through-hole is essentially self-sealing because thereticulated portion 450 will close up enough after the injection probeis withdrawn to create a fluid-dielectric seal within the injection port116.

The optional rigid layer 452 fixes the position of the RFP plug 314within the tapered channel 376′ (see FIG. 18) in embodiments omittingthe LPI 312 or within the first through channel 416 in embodiments thatinclude the LPI 312. The rigid layer 452 includes a through-channel 440that allows an injection probe (e.g., the injection probe pin 136illustrated in FIG. 1A) or a similar structure to pass therethrough whenan injection probe assembly (e.g., the injection probe assembly 130) orother injection device is used to inject the treatment fluid 120 (seeFIG. 1A) into the cable 110.

Referring to FIG. 18, in embodiments of the MIC 100 that omit the LPI312, the optional RFP plug 314 may be positioned inside the taperedchannel 376′ of the injection port 116. The RFP plug 314 has an outershape configured to conform to the shape of a portion of the taperedchannel 376′ adjacent the inner opening 372′. The rigid layer 452 fitssnuggly within that portion of the tapered channel 376′ to anchor theRFP plug 314. This prevents the RFP plug 314 from passing into theinterior chamber 366′ of the MIC body 310′ and from being pushed out ofthe tapered channel 376′ by fluid exiting the cable 110.

By way of another example, referring to FIG. 3, in embodiments of theMIC 100 that include the LPI 312, the optional RFP plug 314 may beinserted into the first through channel 416 and may rest upon theshoulder 418 (see FIGS. 6A and 6B). The RFP plug 314 has an outer shapeconfigured to conform to the shape of a portion of the first throughchannel 416 adjacent the shoulder 418 and fit snuggly within thatportion of the first through channel 416. The narrower portion of thefirst through channel 416 between the shoulder 418 and the inner opening412 prevents the RFP plug 314 from passing into the second throughchannel 426 formed in the LPI 312. The snug fit between the rigid layer452 and the LPI 312 prevents the RFP plug 314 from being pushed out ofthe first through channel 416 by fluid exiting the cable 110.

Referring to FIG. 3, when inserted into the tapered channel 376′ (seeFIG. 18) or the first through channel 416, the optional rigid layer 452(see FIG. 4) is oriented to face toward the cable conductor 202. Inembodiments including the LPI 312, the optional rigid layer 452 (seeFIG. 4) may rest upon the shoulder 418 (see FIGS. 6A and 6B).

Referring to FIG. 3, the reticulated portion 450 (see FIG. 4) of the RFPplug 314 may be configured to be compressed radially by the channel (thetapered channel 376′ depicted in FIG. 18 or the first through channel416) into which the RFP plug 314 is to be inserted. This radialcompression helps assure that the treatment fluid 120 in the reticulatedportion 450 of the RFP plug 314 is in full contact with the walls of thechannel (the tapered channel 376′ depicted in FIG. 18 or the firstthrough channel 416) into which the RFP plug 314 is inserted to therebydielectrically close the injection port 116.

Referring to FIG. 3, the RFP plug 314 is configured to allow insertionof the stem portion 142 (see FIG. 1A) of the cap 140 (or other permanentcap) into the tapered channel 376′ (see FIG. 18) in embodiments omittingthe LPI 312 or the first through channel 416 in embodiments that includethe LPI 312 after the treatment fluid 120 has been introduced. The stemportion 142 may displace and/or compress the RFP plug 314 inside thechannel (the tapered channel 376′ depicted in FIG. 18 or the firstthrough channel 416) into which the RFP plug 314 has been inserted. Forexample, referring to FIG. 30, in embodiments that include the LPI 312and the rigid layer 452 (see FIG. 4), the reticulated portion 450 (seeFIG. 4) may compress against the rigid layer 452 (which is pressedagainst the shoulder 418) to allow the stem portion 142 of the cap 140(or other permanent cap) to be received fully into the first throughchannel 416.

The RFP plug 314 may be constructed in accordance with any of themethods described in U.S. Pat. No. 8,475,194, filed on Oct. 8, 2010,titled Reticulated Flash Prevention Plug, which is incorporated hereinby reference in its entirety. For example, the reticulated portion 450of the RFP plug 314 may be fabricated or punched from a reticulatedmaterial having good dielectric strength and resistivity. The term“reticulated” is defined as a grid-like, porous structure which blocksthe passage of items larger than its characteristic pore size, whileletting smaller items and fluids pass therethrough. Non-limitingexamples of suitable reticulated materials include organic spongematerials, synthetic sponge materials, cotton, woven or non-woventextiles, plastic or elastomeric open-celled foams, felt, fiber glass,sintered glass, or sintered ceramic or a solid material modified toallow fluid passage. The reticulated portion 450 of the RFP plug 314 maybe formed from a compressible material with a density of less than 2.5pounds per cubic foot, a 50% compression set of less than 15%, and a 25%compression force deflection less than 0.5 psi, as would be typical of apolyurethane open-celled foam that has been processed to create areticulated structure. The rigid layer 452 of the RFP plug 314 may befabricated from a stiff insulating material, such as epoxy, vulcanizedfiber, fiberglass, a phenolic resin, ceramic, an engineering plastic, orthe like, or it may be metallic.

MIC Conductor

Referring to FIG. 3, the MIC conductor 318 has a compression connector502 connected to an elongated portion 504. The second end portion 302 ofthe MIC 100 includes the elongated portion 504 of the MIC conductor 318and the second end 352 of the MIC body 310. The second end portion 302of the MIC 100 may simulate the cable conductor 202 and one or more ofthe layers 204 (see FIG. 2) of the cable 110 surrounding the cableconductor 202. The elongated portion 504 may be characterized assimulating the cable conductor 202. The insulation portion 334 at thesecond end 352 of the MIC body 310 may be characterized as simulatingthe insulation layer 208 of the cable 110. The insert 336 at the secondend 352 of the MIC body 310 may be characterized as simulating theconductor shield 206 (see FIG. 2) of the cable 110.

Because the second end portion 302 of the MIC 100 may simulate the cableconductor 202 and one or more of the layers 204 (see FIG. 2) surroundingthe cable conductor 202, the second end portion 302 of the MIC 100 maybe connected to any cable accessories configured to be connected to thecable 110. The second end portion 302 of the MIC 100 may either be sizedspecifically for use with the cable accessory 112 (see FIG. 1A) orconfigurable for use with different cable accessories (e.g., byadjusting the length of the elongated portion 504 of the MIC conductor318, the insulation portion 334 at the second end 352 of the MIC body310, and/or the insert 336 at the second end 352 of the MIC body 310).Further, the size and shape of the outer insulation shield 332 adjacentthe second end 352 of the MIC body 310 may be adjusted for use withother cable accessories. The MIC conductor 318 may be rigid or flexibleand may help make up cable length lost during a retrofit.

Referring to FIG. 1A, the MIC conductor 318 may be characterized asproviding an integral component interface with the cable accessory 112.Such an integral component interface may be more reliable thanconnecting the MIC 100 to the cable accessory 112 with a section ofcable or cable stub (not shown). Further, the MIC conductor 318 does notrequire preparation. Thus, an amount of time required to prepare andassemble an interface with the cable accessory 112 is reduced oreliminated completely.

Additionally, the MIC conductor 318 reduces by several inches the totallength of a subassembly that includes both the MIC 100 and the cableaccessory 112 when compared to a subassembly that uses a stub (insteadof the MIC conductor 318) to connect the MIC 100 and the cable accessory112 together. This space savings may be significant because manytransformers, junction boxes, splice boxes, and the like in which theMIC 100 might be installed have limited room for injection equipment(which was not contemplated when the enclosure was designed andinstalled). In other words, the MIC 100 may be installed and used (e.g.,for injection or direct voltage measurements) in locations not designedto accommodate such operations.

Referring to FIG. 8, in the embodiment illustrated, the compressionconnector 502 is connected to the elongated portion 504 by a taperedportion 506. The compression connector 502 has an opening 510 into alongitudinally extending channel 512 configured to receive therein andhouse an end most portion of the exposed end portion 224 (see FIGS. 6Aand 6B) of the cable conductor 202 (see FIGS. 6A and 6B). Referring toFIG. 6A, the compression connector 502 is configured to be placed overthe exposed end portion 224 of the cable conductor 202 (when the cableconductor 202 is inside the VIA assembly 320) and compressed or swagedwithin the VIA assembly 320 to thereby connect the cable conductor 202with both the VIA assembly 320 and the elongated portion 504. By way ofa non-limiting example, the compression connector 502 may be implementedas an electrically conductive hollow cylinder, a bimetal copperextension, a conductive rod (e.g., constructed from aluminum, copper,another electrically conductive metal, and the like) configured to beconnected (e.g., crimped, swaged, fused, welded, or attached using othermethods known in the art) to the exposed end portion 224 (see FIGS. 6Aand 6B) of the cable conductor 202 (see FIGS. 6A and 6B), and the like.

Referring to FIG. 8, the elongated portion 504 may be implemented as anelongated electrically conductive rod that has a generally circularcross-sectional shape with an outer diameter 514 that is substantiallysimilar the outer diameter 226 (see FIG. 2) of the cable conductor 202.Referring to FIG. 1A, the elongated portion 504 has a free end 516 (seeFIG. 8) configured to mate with the fitting 230 of the cable accessory112 and form an electrical connection therewith.

Optional Via Assembly

The optional VIA assembly 320 is configured for use with the LPI 312 andmay be omitted from embodiments (such as the embodiment illustrated inFIG. 18) that do not include the LPI 312. Referring to FIG. 7, whichdepicts the subassembly 330 that includes the VIA assembly 320, thecable 110, and the MIC conductor 318. The VIA assembly 320 includes aVIA body 550, VIA seals 552A and 552B, and a valve assembly 554, but notthe cable 110 and the MIC conductor 318.

Referring to FIG. 9, the VIA body 550 may be fabricated from a malleablematerial, such as metal (e.g., aluminum or stainless steel). The VIAbody 550 has a first end 560 opposite a second end 562. Each of thefirst and second ends 560 and 562 may be implemented as a hollowcylinder or compression connector. FIGS. 9 and 10 depict the first andsecond ends 560 and 562 before they have been swaged. In contrast, FIG.7 depicts the first and second ends 560 and 562 after they have beenswaged.

Referring to FIGS. 9 and 10, the VIA body 550 has an open ended internalchannel 570 that extends from its first opening 572 at the first end 560to its second opening 574 at the second end 562 of the VIA body 550.Referring to FIG. 10, at the first end 560, the VIA body 550 has one ormore first gripping projections 576 that extend into the internalchannel 570. Similarly, at the second end 562, the VIA body 550 has oneor more second gripping projections 578 that extend into the internalchannel 570. The first gripping projections 576 are configured to allowan end most portion of the exposed end portion 223 (see FIGS. 6A and 6B)of the insulation layer 208 (see FIGS. 6A and 6B) to be inserted throughthe first opening 572 and into the internal channel 570. The secondgripping projections 578 are configured to allow the compressionconnector 502 (see FIGS. 6A and 6B) to be inserted through the secondopening 574, into the internal channel 570, and onto the end mostportion of the exposed end portion 224 (see FIGS. 6A and 6B) of thecable conductor 202 (see FIGS. 6A and 6B).

Referring to FIG. 7, the first end 560 may be swaged onto the exposedend portion 223 of the insulation layer 208 of the cable 110, whichcloses and seals the internal channel 570 (see FIGS. 9 and 10) at thefirst end 560 of the VIA body 550. Swaging presses the first grippingprojections 576 (see FIG. 10) into the insulation layer 208 and forms acompression connection therebetween.

The second end 562 may be swaged onto the compression connector 502 ofthe MIC conductor 318, which closes and seals the internal channel 570(see FIGS. 9 and 10) at the second end 562 of the VIA body 550. Swagingpresses the second gripping projections 578 (see FIG. 10) into thecompression connector 502 and forms a compression connectiontherebetween. As shown in FIGS. 6A and 6B, the swaging also presses thecompression connector 502 into the exposed end portion 224 of the cableconductor 202.

Referring to FIG. 7, the swaging at the first and second ends 560 and562 provides fluid-tight circumferential seals at opposite ends of theinternal channel 570 (see FIGS. 9 and 10) and defines a sealed interiorchamber 580 (see FIGS. 6A and 6B) therebetween within the internalchannel 570. As shown in FIGS. 6A and 6B, within the subassembly 330(see FIG. 7), the cable conductor 202 extends through the interiorchamber 580. The swaging at the first and second ends 560 and 562 may beconfigured to withstand injection pressures of about 30 psi to about1000 psi.

Referring to FIGS. 9 and 10, optionally, a first groove 584 is formed inthe VIA body 550 near the first end 560. The optional first groove 584is configured to receive the optional projection 378 (see FIG. 5) of theMIC body 310 (see FIG. 5). Referring to FIG. 6B, engagement between theoptional projection 378 (see FIG. 5) and the optional first groove 584(see FIG. 9) helps maintain the VIA assembly 320 in a desiredlongitudinal position within the MIC body 310.

Referring to FIGS. 9 and 10, optionally, the VIA body 550 may include atleast one projection 586 configured to be received inside the optionalrecess(es) 379 (see FIG. 5) formed in the MIC body 310 (see FIG. 5)within the interior chamber 366 (see FIG. 5). In the embodimentillustrated, the optional projection 586 is positioned adjacent theoptional first groove 584 with the first groove 584 being flanked by theprojection 586 and the first end 560. Referring to FIG. 6B, engagementbetween the optional projection(s) 586 (see FIG. 9) and the optionalrecess(es) 379 (see FIG. 5) helps maintain the VIA assembly 320 in thedesired longitudinal position within the MIC body 310. The VIA body 550may stop sliding along the MIC axis 340 and with respect to the MIC body310 when the optional projection(s) 586 of the VIA body 550 abuts theedge 428 of the LPI 312. This positively locates the VIA body 550axially within the LPI 312.

Referring to FIG. 6B, a second groove 590 is formed in the VIA body 550and positioned to be adjacent the injection port 116 when the VIAassembly 320 is in the desired longitudinal position within the MIC body310. The second groove 590 may be generally cylindrically shaped andhave a curved outer surface. Thus, along the second groove 590, the VIAbody 550 may have a generally circular cross-sectional shape.

Referring to FIGS. 9 and 10, a first seal groove 592A is spacedlongitudinally from the second groove 590 toward the first end 560, anda second seal groove 592B is spaced longitudinally from the secondgroove 590 toward the second end 562. The first and second seal grooves592A and 592B are configured to receive the VIA seals 552A and 552B (seeFIG. 7), respectively. In the embodiment illustrated in FIG. 7, the VIAseals 552A and 552B may be implemented as O-rings constructed from anelastomeric material.

Referring to FIG. 6B, the VIA seals 552A and 552B are compressed betweenthe VIA body 550 and the LPI 312. In this manner, the VIA seals 552A and552B seal off a fluid chamber 600 within the second through channel 426.The second groove 590 (which is positioned longitudinally between thefirst and second seal grooves 592A and 592B shown in FIGS. 9 and 10) iswithin the fluid chamber 600 and the inner opening 412 of the channel416 (within the injection port 116) opens into the fluid chamber 600.Thus, the treatment fluid 120 (see FIG. 1A) injected through theinjection port 116 may be confined within the fluid chamber 600 by theVIA seals 552A and 552B and the LPI 312.

When interfacing with the LPI 312, the VIA seals 552A and 552B may beconfigured to withstand injection pressures of about 30 psi to about1000 psi. The VIA seals 552A and 552B may be implemented as O-ringseals, D-ring seals, and the like.

Referring to FIGS. 9 and 10, an aperture or a through-hole 610 is formedin the VIA body 550 within the second groove 590. Referring to FIG. 6B,the through-hole 610 interconnects the fluid chamber 600 with the sealedinterior chamber 580 within the VIA body 550. The VIA seals 552A and552B seal off or isolate the fluid chamber 600 by formingcircumferential seals between the VIA assembly 320 and the LPI 312 orthe MIC body 310. The injection port 116 is in fluid communication withthe isolated fluid chamber 600. Thus, there is fluidic communication ora fluid pathway between the injection port 116, the fluid chamber 600,the sealed interior chamber 580 within the VIA body 550, and theinterior 122 of the cable 110. The treatment fluid 120 (see FIG. 1A) canreadily flow in either direction between the interior 122 of the cable110 and the injection port 116.

Referring to FIG. 10, the through-hole 610 has an inner portion 612adjacent an outer portion 614. Inside threads 616 (see FIG. 11A) areformed in the VIA body 550 along the inner portion 612 of thethrough-hole 610. The outer portion 614 is wider (e.g., has a largerdiameter) than the inner portion 612. A stop wall or shelf 620 isdefined at the border between the inner and outer portions 612 and 614.

Referring to FIG. 9, in the embodiment illustrated, a portion of the VIAbody 550 surrounding the through-hole 610 has been removed to provide asubstantially planar outer surface 624 surrounding the through-hole 610.However, this is not a requirement. In the embodiment illustrated, thesubstantially planar outer surface 624 extends the entire width of thesecond groove 590 (along the MIC axis 340 shown in FIG. 5).

Referring to FIG. 6B, the through-hole 610 is configured to receive atleast a portion of the valve assembly 554, which restricts the flow ofthe treatment fluid 120 (see FIG. 1A) between the fluid chamber 600 andthe sealed interior chamber 580 within the VIA body 550.

Valve Assembly

Referring to FIG. 11A, the valve assembly 554 includes a valve cartridge630, a biasing member 632 (e.g., a C-spring), and an optional clip 634.As will be explained below, after the valve cartridge 630 is installedin the through-hole 610 formed in the VIA body 550, the biasing member632 is attached to the poppet member 646 (e.g., by the optional clip634). Referring to FIG. 7, the biasing member 632 is positioned withinthe second groove 590 formed in the VIA body 550.

Referring to FIG. 14, the valve cartridge 630 includes an external valveseal 636, a filter 638, and a poppet valve 640 (see FIGS. 12A-13) formedby a valve body 642, an internal valve seal 644, and a movable poppetmember 646. Referring to FIG. 12A, the poppet valve 640 is closed whenthe poppet member 646 is pushed outwardly (e.g., by the biasing member632 and any outwardly directed force created by internal fluid pressure)and the internal valve seal 644 is captured between the poppet member646 and the inside of the valve body 642. Referring to FIG. 12B, thepoppet valve 640 is open when the poppet member 646 is pushed inwardly(e.g., by an injection probe pin 652 illustrated in FIG. 13) and theinternal valve seal 644 is spaced apart from the inside of the valvebody 642.

Referring to FIG. 13, the poppet valve 640 may be opened by insertingthe injection probe pin 652 into and through the injection port 116 andpressing upon either the poppet member 646 or the biasing member 632.The poppet valve 640 may be closed by removing the injection probe pin652 and allowing the biasing member 632 (and any outwardly directedforce created by internal fluid pressure) to bias the poppet member 646outwardly and into a closed position (shown in FIG. 12A). When thepoppet valve 640 is closed, any of the treatment fluid 120 (see FIG. 1A)inside the sealed interior chamber 580 in the VIA body 550 is trappedtherein.

The injection probe pin 652 may be implemented as any injection probeconfigured to inject the injection fluid 120 (see FIG. 1A) into theinjection port 116. By way of a non-limiting example, the injectionprobe pin 652 may be implemented as the injection probe pin 136illustrated in FIG. 1A.

Valve Body

Referring to FIGS. 14 and 15, the valve body 642 has an outer portion670 opposite an inner portion 672. Referring to FIGS. 12A and 12B, theinner portion 672 is configured to be positioned inside the innerportion 612 of the through-hole 610 formed in the VIA body 550. In theembodiment illustrated, the inner portion 672 has outside threads 674configured to threadedly engage with the inside threads 616 of thethrough-hole 610.

Referring to FIGS. 14 and 15, the outer portion 670 has an outwardlyfacing surface 680. Optionally, an outwardly projecting hex-shapedprotrusion 682 may extend outwardly from the surface 680. The protrusion682 may be used to grip the valve body 642 and apply torque to the valvebody 642 to thread the valve body 642 into the through-hole 610 (seeFIGS. 9-12B) during installation and/or removal of the valve cartridge630 (see FIGS. 11A, 12A, 12B and 14).

The surface 680 may extend along an overhang portion 688 configured tobe at least partially received inside the outer portion 614 (see FIGS.12A and 12B) of the through-hole 610. Referring to FIGS. 12A and 12B,the external valve seal 636 (e.g., an O-ring) is positioned on the valvebody 642 between the overhang portion 688 and the outside threads 674.When the valve cartridge 630 is installed in the through-hole 610, theexternal valve seal 636 is positioned between the overhang portion 688and the shelf 620 to form a fluid tight seal therebetween.

Referring to FIG. 15, the valve body 642 has an interior through channel690 defined by an outer sidewall 692. The channel 690 has an outeropening 694 formed in the outer portion 670, and an inner opening 696formed in the inner portion 672 of the valve body 642. In the embodimentillustrated, the channel 690, the outer opening 694, and the inneropening 696 each have a generally circular cross-sectional shape.

Optionally, the inner opening 696 may be defined by an inwardlyextending deformable lip 698 that extends away from the outside threads674 and into the sealed interior chamber 580 (see FIGS. 6A, 6B, and12A-13) in the VIA body 550 when the valve cartridge 630 is installed inthe through-hole 610. The lip 698 is illustrated in FIG. 15 before beingdeformed. In contrast, FIGS. 12A and 12B depict the lip 698 after it hasbeen deformed. As shown in FIGS. 12A and 12B, the lip 698 may bedeformed into the channel 690 to trap the filter 638 therein.

Referring to FIG. 15, a filter stop 700 is formed in the sidewall 692inside the channel 690. The filter stop 700 is spaced outwardly from theinner opening 696. The filter 638 (see FIGS. 12A, 12B, and 14) may beinserted into the channel 690 through the inner opening 696 and pressedagainst the filter stop 700 by deforming the lip 698 (As shown in FIGS.12A and 12B) into the channel 690 to thereby trap the filter 638 betweenthe inwardly bent lip 698 and the filter stop 700.

A valve stop 702 is formed in the sidewall 692 inside the channel 690.The valve stop 702 is spaced outwardly from the filter stop 700. Atapered portion 706 is formed in the sidewall 692 between the valve stop702 and the outer opening 694. In the embodiment illustrated, thetapered portion 706 is spaced outwardly from the valve stop 702. Thetapered portion 706 is adjacent to an outer channel portion 710 thatextends between the tapered portion 706 and the outer opening 694. Inthe embodiment illustrated, the outer channel portion 710 is narrowerthan an inner channel portion 712 that extends from the valve stop 702to the filter stop 700.

Poppet Member

Referring to FIG. 16, the poppet member 646 has a stem portion 730 thatextends outwardly from an inner stop portion 732. The stem portion 730includes an outer overhanging stop portion 740, an outer recessedportion 742, an intermediate portion 744, and an inner recessed portion746. The outer recessed portion 742 is flanked by the outer overhangingstop portion 740 and the intermediate portion 744. Referring to FIG.11A, the optional clip 634 is configured to be clipped onto the outerrecessed portion 742. Returning to FIG. 16, the outer overhanging stopportion 740 includes an inwardly facing stop wall 750 that is adjacentthe outer recessed portion 742. The inwardly facing stop wall 750retains the optional clip 634 (see FIGS. 7, 11A, 12A, and 12B) withinthe outer recessed portion 742. The intermediate portion 744 includes anoutwardly facing stop wall 752 that is adjacent the outer recessedportion 742 and faces the inwardly facing stop wall 750 across the outerrecessed portion 742.

The inner recessed portion 746 is configured to receive at least aportion of the internal valve seal 644 (see FIGS. 12A, 12B, and 14) andretain the internal valve seal 644 between the intermediate portion 744and the inner stop portion 732. The inner recessed portion 746 has anoutwardly facing tapered portion 754 positioned alongside and inwardlyof the internal valve seal 644. As may be viewed in FIGS. 12A and 12B,the internal valve seal 644 extends laterally outwardly beyond theintermediate portion 744 (see FIG. 16). In the embodiment illustrated,the inner stop portion 732 extends laterally outwardly beyond theinternal valve seal 644.

The inner stop portion 732 and at least a portion of the stem portion730 (see FIG. 16) are positioned inside the channel 690 of the valvebody 642. In the embodiment illustrated, the inner stop portion 732, theinner recessed portion 746 (with the internal valve seal 644 receivedtherein), and the intermediate portion 744 are positioned inside thechannel 690 of valve body 642. The intermediate portion 744 ispositioned inside the outer channel portion 710 (see FIG. 15) of thechannel 690 and moves therein. Returning to FIG. 15, the inner stopportion 732 (see FIGS. 12A and 12B) is positioned inside the innerchannel portion 712 of the channel 690 and moves therein between thevalve stop 702 and the filter 638 (see FIGS. 12A and 12B).

The poppet member 646 moves within the channel 690 between a closedposition (see FIG. 12A) and an open position (see FIGS. 12B and 13). Thepoppet valve 640 is closed (see FIG. 12A) when the poppet member 646 isin the closed position. On the other hand, the poppet valve 640 is open(see FIGS. 12B and 13) when the poppet member 646 is moved inwardly fromthe closed position allowing the treatment fluid 120 (see FIG. 1A) toflow through the poppet valve 640.

Referring to FIG. 12A, when the poppet member 646 is in the closedposition, the inner stop portion 732 abuts the valve stop 702 (see FIG.15). This causes the outwardly facing tapered portion 754 to press theinternal valve seal 644 (e.g., an O-ring) against the tapered portion706 (see FIG. 15) of the sidewall 692 (see FIG. 15) and form a fluidtight seal therewith, which prevents the flow of the treatment fluid 120(see FIG. 1A) through the channel 690 of the valve body 642. Thearrangement of the tapered portions 754 and 706 prevents normallyoccurring flash (which is material left on a part from a moldingprocess) on the internal valve seal 644 from interfering with thesealing action occurring within the poppet valve 640. Furthermore byutilizing a tapered interface, the internal valve seal 644 is capturedand is not displaced by fluid flow (characteristic of a radial seal)through the poppet valve 640. Additionally, the poppet member 646 needonly travel a short distance with respect to the valve body 642 toseparate the internal valve seal 644 from the sealing surface(characteristic of a face seal) of the tapered portion 706 (see FIG.15). Any gap defined between the outer channel portion 710 (see FIG. 15)and the poppet member 646 is too small for the internal valve seal 644to pass through. Similarly, any gap defined between the inner stopportion 732 and the valve stop 702 (see FIG. 15) is also too small forthe internal valve seal 644 to pass through. Thus, the internal valveseal 644 is trapped between the tapered portion 706 (see FIG. 15) andthe tapered portion 754 (see FIG. 16) of the poppet member 646 and formsa fluid tight seal therebetween.

On the other hand, referring to FIG. 12B, the poppet valve 640 is openwhen the inner stop portion 732 is spaced inwardly from the valve stop702 (see FIG. 15), which spaces the internal valve seal 644 inwardlyapart from the tapered portion 706 of the sidewall 692. This allows thetreatment fluid 120 to flow through the channel 690 of valve body 642.Further inward movement of the poppet member 646 may terminate when theinner stop portion 732 contacts the filter 638 or the biasing member 632contacts the outer portion 670 of valve body 642.

The channel 690 of the valve body 642 allows the treatment fluid 120 toflow therethrough (and into the interior chamber 580 of the VIA body550) at between about 30 psi and about 1000 psi when the poppet valve640 is open (or the poppet member 646 is in the open position).Similarly, the poppet valve 640 is configured to hold an internalpressure (e.g., between about 30 psi and about 1000 psi) inside theinterior chamber 580 of the VIA body 550 when the poppet valve 640 isclosed (or the poppet member 646 is in the closed position).

In some embodiments, the poppet member 646 may self-align within thevalve body 642 as the poppet member 646 moves from the open position tothe closed position. In other words, the poppet valve 640 may beself-aligning with self-centering seals.

Referring to FIGS. 16 and 17, at least an outer-most portion of theintermediate portion 744 has a cross-sectional shape that differs fromthe cross-sectional shape of the outer channel portion 710 (see FIG. 15)of the channel 690 and allows the treatment fluid 120 (see FIG. 1A) toflow through the channel 690 between the intermediate portion 744 andthe valve body 642 (see FIG. 15). As mentioned above, in the embodimentillustrated, the channel 690 (see FIG. 15) has a generally circularcross-sectional shape. In the embodiment illustrated, the intermediateportion 744 also has a generally circular cross-sectional shape but theintermediate portion 744 includes one or more longitudinally extendingflat portions 760A-760D that each create a fluid passage 762 (see FIG.12B) between the intermediate portion 744 and the valve body 642 when inthe poppet valve 640 is open (as shown in FIG. 12B).

In the embodiment illustrated, the flat portions 760A-760D do not extendthe full length of the intermediate portion 744. Thus, the intermediateportion 744 includes a stop portion 764 positioned between the flatportions 760A-760D and the inner recessed portion 746. When the poppetvalve 640 is closed (as shown in FIG. 12A), the stop portion 764 ispositioned inside the outer channel portion 710 (see FIG. 15) and atleast partially blocks access to the fluid passages 762 (see FIG. 12B).This prevents the internal valve seal 644 from traveling (or extruding)outwardly through the outer channel portion 710 (between theintermediate portion 744 and the valve body 642), which allows thepoppet valve 640 to operate at higher pressures. The stop portion 764may be configured (e.g., have a sufficient width or diameter) such thatas the poppet member 646 travels toward the closed position (see FIG.12A) pressures above and below the internal valve seal 644 areapproximately equal (that is—the seal is not yet acting to stop flow)before the flat portions 760A-760D enter the outer channel portion 710.

At least an outer-most portion of the inner stop portion 732 has across-sectional shape that differs from the cross-sectional shape of theinner channel portion 712 (see FIG. 15) of the channel 690 and allowsthe treatment fluid 120 (see FIG. 1A) to flow through the channel 690between the inner stop portion 732 and the valve body 642. As mentionedabove, in the embodiment illustrated, the channel 690 has a generallycircular cross-sectional shape. In the embodiment illustrated, the innerstop portion 732 also has a generally circular cross-sectional shape butthe inner stop portion 732 includes one or more longitudinally extendingflat portions 770A-770D that each create a fluid passage 772 (see FIG.12B) between the inner stop portion 732 and the valve body 642 when inthe poppet valve 640 is open (as shown in FIG. 12B).

The generally circular cross-sectional shapes of the intermediateportion 744 and the inner stop portion 732 act within the innerdiameters of the outer channel portion 710 and the inner channel portion712 to guide the poppet member 646 within the valve body 642.

Filter

Referring to FIG. 14, the filter 638 has an outer cross-sectional shapethat corresponds to the cross-sectional shape of an innermost portion ofthe channel 690 (see FIG. 15) defined by the lip 698 (see FIG. 15). Asmentioned above, in the embodiment illustrated, the channel 690 has agenerally circular cross-sectional shape. Thus, in the embodimentillustrated, the filter 638 has a generally circular cross-sectionalshape. For example, the filter 638 may be generally cylindrically shapedor disk shaped. By way of non-limiting examples, the filter 638 may be ascreen, a sintered metal disk, or the like. The filter 638 may beconstructed from any suitable filtering medium known in the art.

Referring to FIGS. 12A and 12B, the filter 638 is positioned in the endof the valve body 642 and retains the poppet member 646 within thechannel 690 during handling. Referring to FIG. 7, the filter 638 (seeFIGS. 12A, 12B, and 14) may also help protect the valve assembly 554from contaminants that may flow out of the cable 110 (e.g., during theinjection process). Referring to FIGS. 12A and 12B and as describedabove, the filter 638 may be held in place by deforming the lip 698(e.g., in one or more places, or continuously) inwardly into the channel690. Alternatively, the filter 638 may be held in place by a retainingclip, interference fit, welding, brazing, soldering, or other meansknown in the art.

Optional Clip

Referring to FIG. 11A, the optional clip 634 is clipped to the outerrecessed portion 742 of the poppet member 646 after the valve body 642has been screwed into the through-hole 610 of the VIA body 550 andsecures the poppet member 646 to the biasing member 632. In theembodiment illustrated, the clip 634 is generally disk-shaped andincludes a cutout 780 that defines a generally E-shaped or C-shaped bodyportion 782. The body portion 782 has a first curved arm 784 thatextends around the cutout 780 toward a second curved arm 786. An opening790 into the cutout 780 is formed between free ends 794 and 796 of thearms 784 and 786, respectively. The opening 790 is configured to receivethe outer recessed portion 742 of the poppet member 646 laterally intothe cutout 780. The arms 784 and 786 are sufficiently rigid to clip ontoand grip the outer recessed portion 742 when the outer recessed portion742 is received fully inside the cutout 780. By way of non-limitingexamples, the clip 634 may be constructed from metal, plastic, ceramic,and the like. Further, other shapes may be used to construct the clip634.

Biasing Member

FIGS. 7, 11A, 12A-13, and 23A depict an embodiment of the biasing member632 configured for use with the optional clip 634. FIG. 11B depicts analternative biasing member 632′ for use in embodiments of the MIC 100that omit the optional clip 634.

Referring to FIG. 11A, in the embodiment illustrated, the biasing member632 is implemented as a C-spring with a curved body 800. In suchembodiments, the C-spring creates a strong sealing force withoutsignificantly increasing the size (e.g., outer diameter) of the VIAassembly 320 laterally compared to other types of springs (e.g., coilsprings). Also, the C-spring provides a large target area for theinjection probe pin 652 (see FIG. 13), and remains nearly perpendicularto the poppet member 646 when compressed by the injection probe pin 652.Alternatively, the biasing member 632 may be implemented as a leafspring (not shown).

By way of a non-limiting example, the body 800 may be implemented as acurved metal band. The body 800 has a first end portion 802 opposite asecond end portion 804 and an intermediate portion 806 between the firstand second end portions 802 and 804. A through-hole 810 is formed in theintermediate portion 806. The through-hole 810 may be positioned aboutmidway between the first and second end portions 802 and 804. Theintermediate portion 806 may include about two thirds of the length ofthe body 800, and radially may include a portion within about 25 degreesto either side of the center of the through-hole 810.

Referring to FIG. 7, when the VIA assembly 320 is fully assembled, thebiasing member 632 is positioned within the second groove 590 formed inthe VIA body 550. At least a portion of the intermediate portion 806surrounding the through-hole 810 is spaced outwardly from the VIA body550. The first and second end portions 802 and 804 (see FIG. 11A) abutthe VIA body 550 and slide therealong circumferentially within thesecond groove 590. The second groove 590 shields the biasing member 632when the VIA assembly 320 is handled by the operator (e.g., when theoperator inserts the subassembly 330 into the MIC body 310).

The through-hole 810 is configured to allow the outer overhanging stopportion 740 (see FIG. 16) of the poppet member 646 to pass therethrough.In the embodiment illustrated, the through-hole 810 has an innerdiameter that is larger than an outer diameter of the outer overhangingstop portion 740 (see FIG. 16) of the poppet member 646.

Referring to FIG. 11A, when the VIA assembly 320 (see FIGS. 3, and 7) isfully assembled, the stem portion 730 (see FIGS. 16 and 17) of thepoppet member 646 extends outwardly from the valve cartridge 630 and theouter recessed portion 742 is positioned within the through-hole 810.The clip 634 is clipped to the outer recessed portion 742 of the poppetmember 646 between the outer overhanging stop portion 740 (see FIG. 16)and the intermediate portion 806 of the biasing member 632. The clip 634is too large to pass through the through-hole 810 and prevents theintermediate portion 806 of the biasing member 632 from moving outwardlybeyond the inwardly facing stop wall 750 (see FIG. 16) to therebyremovably tether the biasing member 632 to the outer recessed portion742 of the poppet member 646. The intermediate portion 744 (see FIGS.12A, 12B, 16, and 17) of the poppet member 646 is too wide to passthrough the through-hole 810 and traps the intermediate portion 806between the outwardly facing stop wall 752 (see FIGS. 16 and 17) and theclip 634. Referring to FIG. 12A, the biasing member 632 bears againstthe clip 634 and presses the clip 634 against the inwardly facing stopwall 750 (see FIG. 16) to thereby bias the poppet member 646 outwardlyand toward the closed position. In other words, the biasing member 632applies an outwardly directed biasing force to the poppet member 646that biases the poppet valve 640 closed.

In alternate embodiments (not shown), other retaining means may be usedto attach the poppet member 646 to the biasing member 632 (e.g., thebiasing member 632) instead of the optional clip 634. For example, theouter recessed portion 742 (see FIGS. 16 and 17) of the poppet member646 may be omitted and a through-hole (not shown) formed in the stemportion 730 of the poppet member 646. Then, after the stem portion 730is positioned within the through-hole 810 with the through-hole (notshown) spaced outwardly from the biasing member 632, a pin (not shown)may be inserted into the through-hole (not shown). The pin prevents thestem portion 730 of the poppet member 646 from traveling inwardlythrough the through-hole 810. By way of another non-limiting example,the outermost portion of the stem portion 730 could be deformed (e.g.,flatten into a larger diameter) after passing through the through-hole810 such that the deformed portion can no longer pass through thethrough-hole 810. By way of yet another non-limiting example, a fastener(e.g., a large headed screw or nut) that will not pass through thethrough-hole 810 could be fastened to (e.g., threaded onto) theoutermost portion of the stem portion 730 after the stem portion 730 ispositioned within the through-hole 810.

As mentioned above, FIG. 11B depicts the biasing member 632′ for use inembodiments of the MIC 100 that omit the optional clip 634. Referring toFIG. 11B, the biasing member 632′ differs from the biasing member 632 inonly one respect, namely, the biasing member 632′ includes athrough-hole 810′ instead of the through-hole 810. Otherwise, thebiasing member 632′ is substantially identical to and provides the samefunctionality as the biasing member 632. Like the biasing member 632,the biasing member 632′ bears against the inwardly facing stop wall 750(see FIG. 16) of the poppet member 646 to thereby bias the poppet member646 outwardly and toward the closed position. In other words, thebiasing member 632′ applies the outwardly directed biasing force to thepoppet member 646 that biases the poppet valve 640 closed.

The through-hole 810′ has a first hole portion 812 configured to allowthe outer overhanging stop portion 740 (see FIG. 16) of the poppetmember 646 to pass therethrough. The through-hole 810′ has a second holeportion 814 configured to prevent the outer overhanging stop portion 740(see FIG. 16) of the poppet member 646 from passing therethrough. Thefirst and second hole portions 812 and 814 are interconnected by achannel portion 816. The channel portion 816 is configured to allow theouter recessed portion 742 (see FIGS. 16 and 17) of the poppet member646 to travel between the first and second hole portions 812 and 814.Referring to FIG. 11A, the VIA assembly 320 (see FIGS. 3, and 7) isassembled by inserting the outer overhanging stop portion 740 (see FIG.16) of the poppet member 646 through the first hole portion 812 (seeFIG. 11B) and positioning the outer recessed portion 742 (see FIGS. 16and 17) of the poppet member 646 in the first hole portion 812. Then,the outer recessed portion 742 (see FIGS. 16 and 17) of the poppetmember 646 is slid through the channel portion 816 (see FIG. 11B) fromthe first hole portion 812 (see FIG. 11B) to the second hole portion 814(see FIG. 11B). Because the outer overhanging stop portion 740 (see FIG.16) of the poppet member 646 cannot pass through the second hole portion814, the biasing member 632′ is trapped between the inwardly facing stopwall 750 (see FIG. 16) and the outwardly facing stop wall 752 (see FIGS.16 and 17).

Because the biasing member 632′ is substantially identical to andprovides the same functionality as the biasing member 632, for the sakeof brevity, the operation of the VIA assembly 320 has been describedbelow with respect to the biasing member 632. However, this descriptionalso applies to the biasing member 632′.

Referring to FIG. 12B, when the biasing member 632 is pressed inwardly,the intermediate portion 806 (see FIG. 11A) of the biasing member 632presses on the outwardly facing stop wall 752 (see FIGS. 16 and 17) ofthe poppet member 646. When the biasing member 632 and/or the poppetmember 646 is pressed upon with sufficient inwardly directed activationforce to overcome both the outwardly directed biasing force of thebiasing member 632 and any outwardly directed force created by internalfluid pressure, the poppet member 646 will move inwardly and open thepoppet valve 640. By way of a non-limiting example, the activation forcemay be at least 0.5 pound-force. By way of another non-limiting example,the activation force may be between 1.3 pound-force and 1.8 pound-force.

Referring to FIG. 13, the poppet valve 640 may be opened by pressingonly on the intermediate portion 806 (see FIG. 11A) of the biasingmember 632 and not on the poppet member 646 directly. This allows thepoppet valve 640 to be opened even when the poppet valve 640 is notprecisely aligned with the injection port 116. Thus, the injection probepin 652 may open the poppet valve 640 by pressing on the biasing member632 at a first location that is up to 25 degrees away from a secondlocation at which the biasing member 632 is connected to the poppetmember 646.

Thus, so long as the intermediate portion 806 is adjacent the injectionport 116, the poppet valve 640 may be opened. In other words, atechnician (or operator) in the field need not precisely align thepoppet valve 640 with the injection port 116. Instead, the operator mayalign the poppet valve 640 with the injection port 116 rotationally byeye by aligning the alignment feature 338 on the first end 350 of theMIC body 310 with a reference mark 820 (see FIGS. 1A and 1B) on theinsulation shield 210 of the cable 110 outside the MIC body 310.Requiring less than a precise alignment is useful because it can bedifficult to achieve a precise alignment in the field. For example,referring to FIG. 7, crimping and/or swaging can lengthen and/or deformthe cable conductor 202 (see FIGS. 3, 6A, and 6B), the first and secondends 560 and 562, and/or the compression connector 502. Further, suchlengthening and/or deformation will vary in magnitude as crimping dieswear and depends upon the precise location (e.g., longitudinally andcircumferentially) of each crimp or swage. The stochastic nature of thisprocess confounds precise alignment.

Referring to FIG. 13, as explained above, each of the biasing members632 and 632′ may be characterized as serving dual purposes:

1) biasing the poppet member 646 toward a closed position (see FIG.12A); and

2) opening the poppet valve 640 when pressed inwardly (e.g., by theinjection probe pin 652) with sufficient inwardly directed force toovercome the outwardly directed biasing force of the biasing member 632(or alternatively, the biasing member 632′) and any outwardly directedforce created by internal fluid pressure.

Referring to FIG. 3, while the VIA assembly 320 is illustrated as beinga subcomponent of the MIC 100, the VIA assembly 320 may also be used inother injection components, such as injection elbows and injectionsplices. In such embodiments (not shown), the valve assembly 554 (seeFIGS. 6B, 7, and 11A) is positioned inside the injection componentadjacent its injection port, and the VIA seals 552A and 552B (see FIGS.6B, 7, and 11A) seal the valve assembly 554 within a fluid chambersubstantially similar to the fluid chamber 600 (see FIGS. 6B and12A-13).

Installation

FIG. 20 is a flow diagram of a method 850 of installing the MIC 100between the cable 110 and the cable accessory 112. The method 850 isperformed by a human operator. The method 850 will be described withrespect to an embodiment of the MIC 100 that includes the optional LPI312 and the optional VIA assembly 320.

In first block 852, the operator prepares the cable 110 to be connectedto both the VIA assembly 320 and the MIC conductor 318 to form thesubassembly 330. For example, referring to FIG. 3, the operator removesend portions of the cable jacket 214 (see FIG. 2) and the neutrals 212(see FIG. 2) from the end 220 of the cable 110 to expose the end portion222 of the insulation shield 210. Then, an end portion of the exposedend portion 222 of the insulation shield 210 is removed to expose theend portion 223 of the insulation layer 208. Finally, end portions ofthe exposed end portion 223 of the insulation layer 208 and theconductor shield 206 (see FIG. 2) underneath the exposed end portion 223are removed to expose the end portion 224 of the cable conductor 202.

In next block 854, the operator slides the VIA assembly 320 onto the end220 of the cable 110. The exposed end portion 224 of the cable conductor202 is positioned inside the second end 562 of the VIA body 550, and theexposed end portion 223 of the insulation layer 208 is positioned insidethe first end 560 of the VIA body 550.

Next, in block 856, the operator inserts the compression connector 502of the MIC conductor 318 into the second end 562 of the VIA body 550with the exposed end portion 224 of the cable conductor 202 positionedinside the longitudinally extending channel 512.

Then, in block 858, the operator rotates the VIA assembly 320 to placethe poppet valve 640 of the valve assembly 554 in a desired position.This allows the operator to control in which direction the injectionport 116 extends outwardly away from the VIA assembly 320.

In block 860, the operator performs swaging operations on the first andsecond ends 560 and 562 of the VIA body 550 to complete the subassembly330. In block 862, the compression connector 502 and the second end 562of the VIA body 550 may be swaged together onto the cable conductor 202before the first end 560 of the VIA body 550 is swaged onto the exposedend portion 223 of the insulation layer 208.

In block 862, the operator places the reference mark 820 (see FIG. 1A)on the exposed end portion 222 of the insulation shield 210. Thereference mark 820 is aligned longitudinally with the poppet valve 640of the valve assembly 554. The reference mark 820 indicates the desiredrotational orientation of the injection port 116.

In block 864, the operator slides the MIC body 310 over the subassembly330 by inserting the free end 516 of the elongated portion 504 of theMIC conductor 318 into the first channel opening 360 of the MIC body 310with the injection port 116 aligned with the reference mark 820 (seeFIG. 7) on the insulation shield 210. Then, the operator slides the MICbody 310 along the subassembly 330 until movement along the MIC axis 340is halted by interference between the VIA body 550 and at least one ofthe MIC body 310 and the LPI 312. For example, the MIC body 310 may stopsliding with respect to the subassembly 330 when the optional projection378 of the MIC body 310 is received by the optional first groove 584 ofthe VIA body 550 and/or the optional projection(s) 586 of the VIA body550 is received inside the optional recess(es) 379 formed in the MICbody 310. By way of another non-limiting example, the MIC body 310 maystop sliding with respect to the subassembly 330 when a tapered face ofthe projection 586 mates with (or abuts) a tapered face of the edge 428of the LPI 312, which positively axially locates the VIA body 550 withinthe LPI 312 and positions the poppet valve 640 adjacent the inneropening 412 (see FIGS. 6A and 6B). At this point, referring to FIG. 3,the cable 110 extends outwardly from the internal channel 356 throughthe first channel opening 360 and the MIC conductor 318 extendsoutwardly from the internal channel 356 through the second channelopening 362.

Returning to FIG. 20, in block 866, the operator rotates the MIC body310 to align the alignment feature 338 with the reference mark 820 (seeFIG. 1A) on the exposed end portion 222 of the insulation shield 210.This aligns the injection port 116 with the poppet valve 640 of thevalve assembly 554.

Referring to FIG. 1A, in optional block 867 (see FIG. 20), the operatormay rotate the fitting 230 and/or the MIC conductor 318 such that whenthe cable accessory 112 is assembled, the cable accessory 112 will be inthe correct orientation to be coupled to the elbow bushing 256.

Then, in block 868 (see FIG. 20), the operator attaches the fitting 230to the free end 516 of the elongated portion 504 of the MIC conductor318 to obtain the assembly shown in FIG. 1B. For example, the operatormay crimp the compression connector 232 of the fitting 230 onto the freeend 516.

Returning to FIG. 20, in block 870, the operator assembles the cableaccessory 112 (see FIG. 1A). For example, referring to FIG. 1A, theoperator may insert the second end 352 (see FIG. 3) of the MIC body 310and the elongated portion 504 (with the fitting 230 connected to thefree end 516) into the housing 240 through the opening 242. The secondend 352 of the MIC body 310 and the elongated portion 504 extend throughthe first branch 248 of the internal L-shaped channel 246 and positionthe threaded hole 234 of the fitting 230 at or near the intersection ofthe first and second branches 248 and 250. The operator may insert thecontact probe 236 into the second branch 250 through the opening 252 andattach the contact probe 236 to the fitting 230 by screwing the threadedend 238 of the contact probe 236 into the threaded hole 234 of thefitting 230. Next, the operator may place the housing 240 over the elbowbushing 256 to thereby insert the elbow bushing 256 into the housing 240(via the opening 252) and connect the elbow bushing 256 to the contactprobe 236.

In optional block 872, the operator connects the cable accessory 112 toother electrical equipment (not shown).

Then, the method 850 terminates.

Referring to FIG. 1A, after the method 850 (see FIG. 20) has beenperformed, the MIC 100 is ready for the injection of the treatment fluid120. As mentioned above, the MIC 100 may be configured to withstandinjection pressures of about 30 psi to about 1000 psi. Using higherinjection pressures may accelerate the treatment of the cable 110.

Injection Probe Assembly

Referring to FIG. 1A, as mentioned above, the MIC 100 is connectedbetween the cable 110 and the cable accessory 112. The injection probeassembly 130 may be used to inject the treatment fluid 120 into theinjection port 116 of the MIC 100. The injection probe assembly 130 maybe configured to inject the treatment fluid 120 at injection pressuresof about 30 psi to about 1000 psi. The injected treatment fluid flowsinto the interior 122 (see FIG. 2) of the cable 110. The assembly 114may be characterized as being an entry site. The treatment fluid 120injected into the cable 110 may flow therethrough to an exit site (notshown) whereat at least a portion of the injected fluid exits theinterior 122 (see FIG. 2) of the cable 110. Fluid exiting the cable 110at the exit site (not shown) indicates that the interior 122 has beenfilled with the treatment fluid 120.

Cable accessories (e.g., the cable accessory 112) may, at times, operatepartially or fully submerged under water. For example, a transformer(not shown) to which the cable accessory 112 is connected may be housedin an underground vault (not shown) subjected to flooding. Injectionequipment (e.g., the injection probe assembly 130) may be connected to acable (e.g., the cable 110) within the flooded underground vault.

Unfortunately, currently available technology used to inject thetreatment fluid 120 into the interior of an energized cable presents asafety risk when used in locations that may be subject to flooding. Thetreatment fluid 120 within the tube 132, the fluid source 134 (e.g., atank), and any connections therebetween may come into fluidic contactwith an energized cable conductor (like cable conductor 202). While thetreatment fluid 120 is non-conductive and normally flowing into thecable at the entry site, sometimes a portion of the treatment fluid 120injected into the cable may flow backwardly and out of the cable at theentry site. This backward flow may be caused by thermal expansion in thecable or pressure loss in the fluid source 134 (e.g., a tank). The backflowing fluid exiting the cable may be contaminated with conductiveparticles, which transform the electrically non-conductive treatmentfluid 120 into an electrically semi-conductive fluid. At the exit site,the portion of the treatment fluid 120 exiting the cable may becontaminated with water loaded with ions that make the exiting fluidelectrically semi-conductive or conductive. When the cable is energized,the contaminated (now electrically semi-conductive or conductive)treatment fluid can transmit potential from the cable conductor.Therefore, if the contaminated treatment fluid is not isolated from theflood water, the operator may be injured by current flowing from thecable through the contaminated treatment fluid and into the flood water.This condition presents a significant safety risk to the human operator.Any current flowing to ground from the cable conductor can quicklyescalate into a full discharge resulting in loss of power and damage tothe cable and equipment.

In a prior art injection component (e.g., an injection cap illustratedin U.S. Pat. No. 4,946,393), the energized treatment fluid is oftenseparated from the flood water by only one or more threads of a threadedconnection between the injection component and a tubing connector (notshown) coupled to the tube 132. For example, the distance between theenergized treatment fluid and the flood water may be as little as thewidth (e.g., about 0.06 inch) of a single thread of the tubingconnector. This distance is along the interface of two electricallyinsulating materials.

As mentioned above, the treatment fluid 120 may be made electricallysemi-conductive or conductive by external contamination. As will beexplained below, the injection probe assembly 130 includes sealspositioned to provide separation between the energized and potentiallycontaminated treatment fluid and the outside environment (which mayinclude flood water) to prevent the flow of current from the cableconductor 202 (see FIG. 2) through energized and contaminated treatmentfluid and into the outside environment (e.g., into the flood water). Byway of a non-limiting example, the injection probe assembly 130 and themanner in which the injection probe assembly 130 connects to the LPI 312of the MIC 100 may provide a minimum distance of about 0.30 inchesbetween the treatment fluid 120 and the outside environment along anyinterfaces between insulating materials positioned along the flow of thetreatment fluid 120 into the MIC body 310 or the MIC body 310′ (see FIG.18). By way of another non-limiting example, the injection probeassembly 130 and the MIC 100 may provide a minimum distance of about0.10 inches between the treatment fluid 120 and the outside environmentthrough any solid insulating materials positioned along the flow of thetreatment fluid 120 into the MIC body 310 or the MIC body 310′ (see FIG.18).

FIG. 21 is an enlarged portion of FIG. 1A showing the injection probeassembly 130 and the injection port 116 of the MIC 100. The injectionprobe assembly 130 may be used with any injection component (e.g., theMIC 100, an injection elbow, an injection splice, and the like) thatincludes an injection port like the injection port 116. Referring toFIG. 21, the injection probe assembly 130 includes the injection probepin 136, which includes an elongated pin 902 connected to a probe tip904. Referring to FIG. 23A, the elongated pin 902 and the probe tip 904(see FIGS. 21 and 22) are used to open the poppet valve 640 by pressinginwardly on the poppet member 646 (see FIGS. 11A, 12A-14, 16, and 17),the biasing member 632, or the biasing member 632′ (see FIG. 11B).

FIG. 22 is an exploded perspective view of the injection probe assembly130. Referring to FIG. 22, in addition to the injection probe pin 136(see FIGS. 1A, 21, and 22), the injection probe assembly 130 includesseals 906A-906G, a tapered injection nozzle 910, a poppet member or aninner cap 912, a biasing member 914 (e.g., a coil spring), an outer cap920, an elbow shaped connector 922, a fitting 924, a ferrule sleeve 926,a ferrule cone 928, and a connector 930 (e.g., a nut). By way ofnon-limiting examples, the ferrule sleeve 926, the ferrule cone 928, andthe connector 930 may be purchased from JACO Manufacturing Company ofBerea, Ohio. However, other components may be used.

As will be described below, the seals 906B, 906E, and 906G and theferrule sleeve 926 help prevent water 940 (see FIGS. 24A and 24B) fromentering the injection probe assembly 130 and the MIC 100 (see FIG. 21).For ease of illustration, both the cable 110 (see FIG. 6A) and the MICconductor 318 (see FIG. 6A) have been omitted from FIGS. 24A and 24B. InFIG. 24A, the water 940 trying to infiltrate the injection probeassembly 130 and the MIC 100 has been illustrated using bold lines W1-W6extending between adjacent components. As may be viewed in FIG. 24A, theseals 906B, 906E, and 906G and the ferrule sleeve 926 stop this waterinfiltration.

Referring to FIG. 24B, the seals 906A, 906D and 906F help prevent thetreatment fluid 120 from exiting the injection probe assembly 130 and/orthe injection port 116. In FIG. 24B, the treatment fluid 120 trying toescape from the injection probe assembly 130 and the injection port 116has been illustrated using bold lines TF1-TF6 extending between adjacentcomponents. As may be viewed in FIG. 24B, the seals 906A, 906D and 906Fretain the treatment fluid 120 inside the injection probe assembly 130and the injection port 116 and prevent the treatment fluid 120 fromescaping.

Further, as shown in FIGS. 24A and 24B, the bold lines W1-W6illustrating the potentially infiltrating water 940 and the bold linesTF1-TF6 illustrating the potentially escaping treatment fluid 120 arespaced apart from one another by at least a minimum distance (e.g.,about 0.30 inches). In other words, the potentially infiltrating water940 is kept apart from the potentially escaping treatment fluid 120 byat least the minimum distance (e.g., about 0.30 inches).

Referring to FIG. 22, the elongated pin 902 has a tethered end 950opposite a free end 952. The probe tip 904 is attached to the free end952. Referring to FIG. 23A, the elongated pin 902 spaces the probe tip904 (see FIGS. 21 and 22) away from the tapered injection nozzle 910 andfurther into the injection port 116 when the injection probe assembly130 is used to inject the treatment fluid 120 into the injection port116 of the MIC 100. The elongated pin 902 may be constructed frompultruded fiberglass, which is electrically non-conductive. Whilepultruded fiberglass will fracture when bent too far, the elongated pin902 will not break into two pieces and leave a portion including theprobe tip 904 inside the energized MIC 100.

Referring to FIG. 22, the tapered injection nozzle 910 has free firstend portion 956 opposite a second end portion 958. In the embodimentillustrated, the free first end portion 956 has a generally hexagonalcross-sectional shape that may be gripped so that torque may be appliedto the second end portion 958. The torque applied rotates the taperedinjection nozzle 910 for the purposes of coupling the tapered injectionnozzle 910 to the elbow shaped connector 922 and uncoupling the taperedinjection nozzle 910 from the elbow shaped connector 922. The taperedinjection nozzle 910 narrows toward its free first end portion 956. Thesecond end portion 958 is configured to be removably coupled to theelbow shaped connector 922 inside the outer cap 920. Referring to FIG.23A, an open-ended internal through-channel 960 extends between thefirst and second end portions 956 and 958. The elongated pin 902 extendsthrough the internal through-channel 960 and outwardly therefrom beyondthe first end portion 956. The internal through-channel 960 has a largercross section than the elongated pin 902 which allows the treatmentfluid 120 (see FIGS. 24A and 24B) to flow through the internalthrough-channel 960 alongside the elongated pin 902.

Referring to FIG. 25, the tapered injection nozzle 910 has a chamber 964formed in the second end portion 958. The tapered injection nozzle 910has a surface 961 that faces upwardly into the chamber 964. An annularshaped groove 962 is formed in the upwardly facing surface 961. Thegroove 962 is concentric with and spaced apart from the internalthrough-channel 960. Referring to FIG. 23B, as will be described below,the chamber 964 (see FIG. 25) is configured to house the inner cap 912,the biasing member 914, a portion of the elbow shaped connector 922, andthe seals 906C-906E. Referring to FIG. 23A, the internal through-channel960 opens into the chamber 964 (see FIG. 25) and the elongated pin 902extends outwardly from the internal through-channel 960 into the chamber964. Referring to FIG. 25, the chamber 964 is defined by a sidewall 966with inside threads 968 formed therein.

Referring to FIG. 22, in the embodiment illustrated, the taperedinjection nozzle 910 is generally cone shaped and has a generallycircular cross sectional shape. Between its first and second endportions 956 and 958, the tapered injection nozzle 910 has first andsecond spaced apart grooves 970A and 970B that each extendcircumferentially along its outer surface 972. The first groove 970A isnearer the free first end portion 956 than the second groove 970B. Thefirst and second grooves 970A and 970B are configured to at leastpartially receive the seals 906A and 906B, respectively. In theembodiment illustrated, the seals 906A and 906B have been implemented asO-rings.

Referring to FIG. 23A, in embodiments that include the LPI 312, theseals 906A and 906B form fluid tight seals between the tapered injectionnozzle 910 and the portion of the LPI 312 lining the tapered channel 376when the injection probe assembly 130 is inserted into the injectionport 116. Similarly, in embodiments that omit the LPI 312, the seals906A and 906B form fluid tight seals between the tapered injectionnozzle 910 and the MIC body 310′ (see FIG. 18) along the tapered channel376′ (see FIG. 18) when the injection probe assembly 130 is insertedinto the injection port 116. Thus, as illustrated by the bold lines TF1and TF2 in FIG. 24B, the seal 906A prevents the treatment fluid 120 fromflowing backwardly and into the outside environment through theinjection port 116. At the same time, referring to FIG. 24A, asillustrated by the bold lines W1 and W2, the seal 906B prevents thewater 940 from flowing into the MIC 100 from the outside environment viathe injection port 116.

Referring to FIG. 22, the tapered injection nozzle 910 passes partiallythrough the outer cap 920 and is coupled at its second end portion 958to the elbow shaped connector 922 inside the outer cap 920. As may beseen in FIG. 23B, the elongated pin 902 is coupled to the inner cap 912inside the chamber 964 (see FIG. 25). The inner cap 912 anchors theelongated pin 902 inside the chamber 964 and prevents the tethered end950 (see FIG. 22) of the elongated pin 902 from exiting the chamber 964through the internal through-channel 960 (see FIGS. 23A and 25). Thebiasing member 914 abuts the inner cap 912 and applies a biasing forcethereto that biases the inner cap 912 (and the elongated pin 902) towardthe free first end portion 956 (see FIG. 22) of the tapered injectionnozzle 910.

In the embodiment illustrated, the seals 906C-906E have been implementedas O-rings. The seal 906C is positioned inside the groove 962 (see FIG.25) within the chamber 964 (see FIG. 25). The seals 906D and 906E arepositioned between the elbow shaped connector 922 and the taperedinjection nozzle 910 within the chamber 964 (see FIG. 25). Referring toFIG. 24B, as illustrated by the bold lines TF3 and TF4, the seal 906Dhelps prevent the treatment fluid 120 from exiting the injection probeassembly 130 through any gaps that may exist between the taperedinjection nozzle 910 and the elbow shaped connector 922. Referring toFIG. 24A, as illustrated by the bold lines W1 and W2, the seal 906Ehelps prevent the water 940 from infiltrating into the injection probeassembly 130 through any gaps that may exist between the taperedinjection nozzle 910 and the elbow shaped connector 922.

Referring to FIG. 23A, the outer cap 920 has an open-endedthrough-channel 980 formed therein that extends between first and secondopenings 982 and 984. The injection port 116 may be inserted into thethrough-channel 980 through the first opening 982. The elbow shapedconnector 922 extends into the through-channel 980 through the secondopening 984. The tapered injection nozzle 910 is connected to the elbowshaped connector 922 inside the through-channel 980 and extendsoutwardly from the through-channel 980 through the first opening 982.

Referring to FIG. 26, a first channel portion 986 adjacent the firstopening 982 is defined by a skirt portion 988. The first channel portion986 is configured to receive the outer sidewall 368 of the injectionport 116 formed in the insulation portion 334 of the MIC body 310. Theskirt portion 988 is semi-conductive and covers the outer sidewall 368.Referring to FIG. 23A, in embodiments including the LPI 312, the skirtportion 988 contacts the semi-conductive outer insulation shield 332 ofthe MIC body 310 surrounding the base of the outer sidewall 368.Referring to FIG. 18, in embodiments that omit the LPI 312, the skirtportion 988 contacts the semi-conductive outer insulation shield 332′ ofthe MIC body 310′ surrounding the base of the outer sidewall 368′.

The outer cap 920 differs from outer insulated coverings included onconventional injection probes (not shown), which are typicallyconstructed from only electrically insulating material(s). Becauseconventional insulated coverings are constructed from only electricallyinsulating material(s), they suffer from at least two significantlimitations. First, outer insulated coverings prevent the connectionformed between the conventional cap and the injection component frombeing approved or rated for submersible applications in which a voltagedifferential between the voltage in the cable conductor and groundvoltage is 8.8 kilovolts (kV) to 20.5 kV (which is commonly found inmedium voltage systems). Second, outer insulated coverings allow acapacitive charge to be created at and around the injection port of theinjection component. This capacitive charge could injure a humanoperator or lineman.

Referring to FIG. 26, the through-channel 980 has a second channelportion 990 opposite the first channel portion 986. Referring to FIG.23A, the second channel portion 990 (see FIG. 26) is configured to housethe second end portion 958 of the tapered injection nozzle 910. Thesecond end portion 958 is too large to pass through the second opening984 (see FIG. 26) of the outer cap 920. Thus, when the second endportion 958 of the tapered injection nozzle 910 is coupled to the elbowshaped connector 922, a portion 992 (see FIGS. 23B and 26) of the outercap 920 adjacent the second opening 984 is sandwiched between the secondend portion 958 and the elbow shaped connector 922.

Referring to FIG. 21, as mentioned above, the LPI 312 includes theconnectors 404A and 404B (e.g., a pair of projections of a bayonet typeconnector). Referring to FIG. 26, the outer cap 920 includes connectors994A and 994B configured to mate with the connectors 404A and 404B (seeFIG. 21), respectively. In the embodiment illustrated, the connectors994A and 994B are implemented as grooves configured to receive theconnectors 404A and 404B. The connectors 994A and 994B are positionedinside the through-channel 980 between its first and second channelportions 986 and 990.

Optionally, one or more gripping projections 996A and 996B extendoutwardly away from the through-channel 980. In the embodimentillustrated, the gripping projections 996A and 996B are substantiallycollinear and orthogonal to the through-channel 980. The outer cap 920may be gripped by the gripping projections 996A and 996B and twisted.The gripping projections 996A and 996B may be used to rotate the outercap 920 such that the connectors 994A and 994B receive and mate with theconnectors 404A and 404B (see FIG. 21), respectively, when twisted in afirst direction, and disengage with the connectors 404A and 404B,respectively, when twisted in a second direction opposite the firstdirection. In other words, one of the gripping projections 996A and 996Bis pushed upon at the same time the other of the gripping projections996A and 996B is pulled upon. This configuration helps overcome adhesionbetween the outer cap 920 and the MIC 100.

In the embodiment illustrated, the gripping projections 996A and 996Bare positioned with respect to the connectors 994A and 994B to provide avisual indication of whether the outer cap 920 is coupled to oruncoupled from the MIC 100. In the embodiment illustrated, when thesubstantially collinear gripping projections 996A and 996B aresubstantially aligned with the MIC axis 340 (see FIG. 5), the outer cap920 is uncoupled from the MIC 100. On the other hand, the outer cap 920is coupled to the MIC 100 when the substantially collinear grippingprojections 996A and 996B are substantially orthogonal to the MIC axis340 (see FIG. 5).

Referring to FIG. 22, the elbow shaped connector 922 has a first leg1000 and a second leg 1002. In the embodiment illustrated, the first leg1000 is approximately orthogonal to the second leg 1002. The first leg1000 is connected to the tapered injection nozzle 910 (and the outer cap920) and the second leg 1002 is connected to both the fitting 924 andthe tube 132.

Referring to FIG. 27, the first leg 1000 is configured to be at leastpartially received inside the chamber 964 (see FIG. 25). The first leg1000 has outside threads 1008 configured to threadedly engage the insidethreads 968 (see FIG. 25) of the chamber 964 (see FIG. 25). The firstleg 1000 has a lower edge 1010 configured to capture or trap the seal906C (see FIG. 23B) within the groove 962 (see FIG. 25) when the firstleg 1000 is fully threaded into the chamber 964 (see FIG. 25). The firstleg 1000 has a recessed portion 1012 configured to fit inside the seal906D (see FIG. 23B). Referring to FIG. 23B, when the first leg 1000 isfully threaded into the chamber 964 (see FIG. 25), the recessed portion1012 (see FIG. 27) presses the seal 906D against the sidewall 966 (seeFIG. 25) and forms a fluid tight seal between the first leg 1000 and thesidewall 966 of the chamber 964. Returning to FIG. 27, the first leg1000 has a groove 1014E formed therein configured to at least partiallyreceive the seal 906E (see FIG. 22). Referring to FIG. 23B, when thefirst leg 1000 is fully threaded into the chamber 964 (see FIG. 25), theseal 906E is pressed against the sidewall 966.

As shown in FIG. 23B, an L-shaped internal through-channel 1020 extendsthrough the elbow shaped connector 922. Referring to FIG. 27, thethrough-channel 1020 opens into an open valve chamber 1022 in the firstleg 1000 and an open chamber 1024 in the second leg 1002. Referring toFIG. 23B, the valve chamber 1022 is configured to house the inner cap912 (with the tethered end 950 of the elongated pin 902 attachedthereto) and the biasing member 914. The biasing member 914 ispositioned between the inner cap 912 and an interior surface 1025 of thevalve chamber 1022.

Together the first leg 1000 and the second end portion 958 of thetapered injection nozzle 910 functions as a valve housing for a poppetvalve 1023 that is opened by the elongated pin 902. The inner cap 912,which is attached to the elongated pin 902, functions as a moveablepoppet member of the poppet valve 1023. The biasing member 914 biasesthe inner cap 912 toward a closed position. Thus, when the injectionprobe pin 136 (see FIGS. 1A, 21, and 22) is not pressing against thebiasing member 632 (see FIGS. 7, 11A-13 and 23A), the clip 634 (seeFIGS. 7, 11A, 12A, and 12B), or the poppet member 646 (see FIGS. 11A,12A-14, 16, and 17) of the VIA assembly 320, the biasing member 914 maybias the poppet valve 1023 closed. The biasing member 914 also allowsthe injection probe pin 136 (see FIGS. 1A, 21, and 22) to open thepoppet valve 1023 when the injection probe pin 136 is pressed againstdifferent surfaces located at different distances from the free firstend portion 956 of the tapered injection nozzle 910. For example, theinjection probe pin 136 is operable to open the poppet valve 1023 whenpressed against the biasing member 632, the clip 634, or the poppetmember 646. Similarly, the injection probe pin 136 is operable to openthe poppet valve 1023 even if the size and/or position of the componentsvaries due to manufacturing inconsistencies.

In the closed position, the inner cap 912 compresses the seal 906C,which forms a fluid tight seal between the inner cap 912 and the secondend portion 958 of the tapered injection nozzle 910. When the elongatedpin 902 is pressed outwardly with sufficient force to overcome aninwardly directed biasing force of the biasing member 914, the inner cap912 moves outwardly away from the seal 906C and the poppet valve 1023opens. The inner cap 912 is small enough to allow the treatment fluid120 to flow around the inner cap 912, through the valve chamber 1022,and into the internal through-channel 960 when the poppet valve 1023 isopen.

The open chamber 1024 is configured to receive a portion of the fitting924, the tube 132, and the seals 906F and 906G. In the embodimentillustrated, the seals 906F and 906G have been implemented as O-rings.The seal 906F is positioned inside the open chamber 1024 between thetube 132, and the fitting 924. Referring to FIG. 24B, as illustrated bythe bold lines TF5 and TF6, the seal 906F helps prevent the treatmentfluid 120 from exiting the injection probe assembly 130 through any gapsthat may exist between the tube 132, the elbow shaped connector 922, andthe fitting 924. The seal 906F is configured to withstand higherpressures (e.g., about 600 psi) than the ferrule sleeve 926. Thisconfiguration protects the ferrule sleeve 926 (which, depending upon theimplementation details, may withstand about 220 psi) when operating athigher pressures (e.g., about 600 psi) and takes advantage of theferrule sleeve's ability to mechanically hold the tube 132.

Referring to FIG. 24A, the seal 906G is positioned between the elbowshaped connector 922 and the fitting 924 within the open chamber 1024(see FIG. 27). As illustrated by the bold lines W3 and W4, the seal 906Ghelps prevent the water 940 from entering the injection probe assembly130 through any gaps that may exist between the elbow shaped connector922 and the fitting 924.

Returning to FIG. 27, the open chamber 1024 is defined by a sidewall1026 with inside threads 1028 formed therein. Referring to FIG. 23B, theopen chamber 1024 has a narrower portion 1030 configured to receive anend 1032 (see FIG. 22) of the tube 132 (see FIG. 22). A shoulder 1034 isformed in the open chamber 1024 between the inside threads 1028 and thenarrower portion 1030. The seal 906F is positioned against the shoulder1034. The end 1032 of the tube 132 passes through the seal 906F andterminates inside the narrower portion 1030. The seal 906F is pressedagainst the shoulder 1034 by the fitting 924.

The fitting 924 has a first threaded end 1040 opposite a second threadedend 1042. The fitting 924 also has an intermediate portion 1043positioned between the first and second threaded ends 1040 and 1042. Theintermediate portion 1043 has a generally hexagonal cross-sectionalshape that may be gripped so that torque may be applied to the fitting924 to rotate the fitting 924 or hold the fitting 924 in place.

The first and second threaded ends 1040 and 1042 have outside threads1044 and 1046, respectively. The outside threads 1044 of the firstthreaded end 1040 are configured to mate with the inside threads 1028 ofthe elbow shaped connector 922. The first threaded end 1040 has an edgesurface 1050 that abuts and presses on the seal 906F when the firstthreaded end 1040 is fully threaded into the open chamber 1024. Thefitting 924 has a stop portion 1052 spaced apart from the outsidethreads 1044. The seal 906G is positioned between the outside threads1044 and the stop portion 1052. The stop portion 1052 traps the seal906G inside the open chamber 1024 when the first threaded end 1040 isfully threaded into the open chamber 1024. The second threaded end 1042is configured to mate with the connector 930. The fitting 924 has athrough-channel 1060 configured to allow the tube 132 to passtherethrough.

The connector 930 has an open-ended through-channel 1070 with a taperedend 1072 opposite a threaded end 1074. The ferrule cone 928 ispositioned inside the tapered end 1072. The ferrule sleeve 926 extendsfrom the ferrule cone 928 toward the threaded end 1074. The tube 132passes through the ferrule cone 928 and the ferrule sleeve 926 insidethe through-channel 1070. Together, the ferrule cone 928 and the ferrulesleeve 926 line part of the through-channel 1070 and help grip the tube132. The threaded end 1074 has inside threads 1076 configured to matewith the outside threads 1046 of the second threaded end 1042 of thefitting 924. The ferrule sleeve 926 forms a fluid tight seal between thefitting 924 and the tube 132. Thus, the ferrule sleeve 926 helps preventthe water 940 (see FIGS. 24A and 24B) from entering the injection probeassembly 130 and the MIC 100 (see FIG. 21). The ferrule cone 928 andferrule sleeve 926 also helps hold the tube 132 in place but, dependingupon the implementation details, may withstand pressures up to onlyabout 220 psi.

Referring to FIG. 24B, when the treatment fluid 120 is injected usingthe injection probe assembly 130, the pressurized treatment fluid 120travels through the tube 132 and enters the L-shaped internalthrough-channel 1020 formed in the elbow shaped connector 922. Thetreatment fluid 120 next enters the chamber 964 of the tapered injectionnozzle 910 and flows into the internal through-channel 960 alongside theelongated pin 902. Then, the treatment fluid 120 exits the internalthrough-channel 960 and enters the first through channel 416 inembodiments that include the LPI 312 or the tapered channel 376′ (seeFIG. 18) in embodiments that omit the LPI 312. Optionally, the treatmentfluid 120 may pass through the RFP plug 314 (see FIGS. 3, 4, and 23A),which may be positioned within the first through channel 416 or thetapered channel 376′. Then, the treatment fluid 120 enters into thefluid chamber 600 (see FIGS. 6B and 12A-13) in embodiments that includethe LPI 312 (and the VIA assembly 320) or the interior chamber 366′ (seeFIG. 18) in embodiments that omit the LPI 312.

Referring to FIG. 26, by coupling the injection probe assembly 130 tothe injection port 116 using the connectors 994A and 994B and theconnectors 404A and 404B, the connection formed between the injectionprobe assembly 130 and the injection port 116 may withstand higherinjection pressures (e.g., greater than about 30 psi) than connectionsformed between conventional injection assemblies and an injection port,which are typically interference fits. For example, the connectionbetween the injection probe assembly 130 and the injection port 116 mayremained sealed and not leak when the treatment fluid 120 is injected ata pressure within a range of about 30 psi to about 1000 psi. Further,this connection will remained sealed and not leak at pressures below 30psi.

The connectors 994A and 994B are configured to break before theconnectors 404A and 404B. In this manner, the outer cap 920 will notdamage the LPI 312. Further, the outer cap 920 may absorb externalforces and help shield the LPI 312 from damage.

The injection probe assembly 130 may be characterized as includingdouble fluid seals at all points of separation between the voltage ofthe cable conductor 202 and ground voltage to prevent potentiallyconductive fluids (the treatment fluid 120 and the water 940) fromcoming into close contact with one another when at least a portion ofthe MIC 100, the cable 110, the cable accessory 112, and/or injectionprobe assembly 130 is submerged in the water 940. For example, the seals906A and 906B may be characterized as being a first pair of seals thatseparate the treatment fluid 120 from the water 940. Similarly, theseals 906D and 906E may be characterized as being a second pair of sealsthat separate the treatment fluid 120 from the water 940. Finally, theseals 906F and 906G may be characterized as being a third pair of sealsthat separate the treatment fluid 120 from the water 940.

Also, referring to FIG. 1A, the injection probe assembly 130 does nothave a pulling eyelet (like either of the pulling eyelets 258 and 260)that can be mistaken for the pulling eyelet 258 of the cap 257 or thepulling eyelet 260 of the cable accessory 112. Thus, the injection probeassembly 130 will not be mistakenly removed by a lineman who isunfamiliar with injection components. This improves safety becauseremoving a conventional injection assembly that is covering an injectionport alongside an energized cable has been known to cause dangerousflashovers. Further, because the injection probe assembly 130 does nothave a pulling eyelet, the injection probe assembly 130 has a lowerprofile than injection assemblies or devices that include such eyelets,which is advantageous in a space constricted installation where thepulling eyelet may interfere.

Cap

Referring to FIG. 1A, as mentioned above, the skirt portion 144 of thecap 140 is constructed from an electrically semi-conductive material. Aconventional cap is typically coupled to an injection component by adetent ring (not shown) that has been known to separate from theinjection component during normal injection operations performed atpressures not greater than 30 psi. Due to elevation changes and thermalexpansion, pressures within the cable and at its terminations can exceedthe injection pressure.

As mentioned above, the cap 140 may be used to close the injection port116 and seal it from the outside environment whenever the injectionprobe assembly 130 (or other injection device) is not connected to theinjection port 116. When the cap 140 is attached to the injection port116, the stem portion 142 extends into the injection port 116 andprevents fluid from exiting the MIC 100 through the injection port 116thereby isolating and insulating the interior of the MIC 100 from theoutside environment. The cap 140 may remain in place on the injectionport 116 until the completion of a soak period (e.g., about 60 days toabout 90 days), if required. By way of another non-limiting example, thecap 140 may remain in place on the injection port 116 during theelectrical service life of the MIC 100.

Referring to FIG. 31, the cap 140 includes an outer cap 2000 that issubstantially identical to the outer cap 920 (see FIGS. 21-23A and 26)of the injection probe assembly 130. The skirt portion 144 of the cap140 is a subcomponent of the outer cap 2000 and is substantiallyidentical to the skirt portion 988 (see FIGS. 23A and 26) of the outercap 920 (see FIGS. 21-23A and 26).

The outer cap 2000 has an open-ended through-channel 2002 formed thereinthat extends between first and second openings 2004 and 2006. The skirtportion 144 has a lower edge 2008 that defines the first opening 2004into the through-channel 2002. As shown in FIG. 30, the injection port116 may be inserted into the through-channel 2002 through the firstopening 2004. Returning to FIG. 31, a first channel portion 2010adjacent the first opening 2004 is defined by the skirt portion 144. Thethrough-channel 2002 has a second channel portion 2012 opposite thefirst channel portion 2010.

The stem portion 142 has a tethered end 2020 opposite a free end 2022.The tethered end 2020 is attached to the outer cap 2000 inside thesecond channel portion 2012 and closes the second opening 2006. The stemportion 142 extends from its tethered end 2020 through thethrough-channel 2002, exits therefrom through the first opening 2004,and terminates at an end surface 2026 positioned beyond the lower edge2008 of the skirt portion 144.

A semi-conductive outer coating (not shown), such as a semi-conductivelayer of paint, is applied to the outer surface of the cap 140. Thisouter coating (not shown) covers the tethered end 2020 of the stemportion 142 within the second opening 2006. Thus, the entire exposedouter surface of the cap 140 is semi-conductive.

Referring to FIG. 30, when the cap 140 is attached to the injection port116, the stem portion 142 fills and closes the outer opening 410 inembodiments that include the LPI 312 or the outer opening 370′ (see FIG.18) in embodiments that omit the LPI 312. Together, the outer cap 2000and the stem portion 142 completely cover and seal the injection port116. Referring to FIG. 28, the seal formed between the cap 140 and theinjection port 116 is fluid tight and prevents any fluids (e.g., thewater 940 illustrated in FIGS. 24A and 24B) outside the cap 140 and/orthe MIC 100 from entering the injection port 116.

Referring to FIG. 28, in embodiments that include the LPI 312, the stemportion 142 is inserted into the portion of the LPI 312 lining theinjection port 116. In other words, referring to FIG. 30, the stemportion 142 is inserted into the tapered first through channel 416through the outer opening 410. If the RFP plug 314 is positioned insidethe first through channel 416, the end surface 2026 of the stem portion142 may displace and/or compress the RFP plug 314 (against the shoulder418) inside the first through channel 416.

On the other hand, referring to FIG. 18, in embodiments that omit theLPI 312, the stem portion 142 (see FIGS. 1A, 28, 30, and 31) is insertedinto the tapered channel 376′ through the outer opening 370′. If the RFPplug 314 (see FIGS. 3, 4, and 30) is positioned inside the taperedchannel 376′, the end surface 2026 (see FIGS. 30 and 31) of the stemportion 142 may displace and/or compress the RFP plug 314 (against theouter sidewall 368′ adjacent the inner opening 372′ of the taperedchannel 376′) inside the tapered channel 376′.

Referring to FIG. 30, as mentioned above, the cap 140 may becharacterized as being permanent because the cap 140 closes theinjection port 116 electrically. The stem portion 142 is constructedfrom electrically insulating material, and the skirt portion 144 isconstructed from electrically semi-conductive material. The stem portion142 seals the first through channel 416 or the tapered channel 376′ (seeFIG. 18) with electrically insulating material. In embodiments thatinclude the LPI 312, the outer sidewall 368 (formed in the insulationportion 334) is received inside the first channel portion 2010 (see FIG.31) between the stem portion 142 and the skirt portion 144. On the otherhand, referring to FIG. 18, in embodiments that omit the LPI 312, theouter sidewall 368′ (formed in the insulation portion 334′) of the MICbody 310′ is received inside the first channel portion 2010 (see FIG.31) between the stem portion 142 and the skirt portion 144. In thismanner, the skirt portion 144 covers the insulating outer sidewall 368or 368′ with an electrically semi-conductive material. Further, alongits lower edge 2008, the skirt portion 144 contacts the semi-conductiveouter insulation shield 332 of the MIC body 310 (which may be connectedto ground by a ground wire) in embodiments that include the LPI 312 orthe semi-conductive outer insulation shield 332′ (see FIG. 18) of theMIC body 310′ (which may be connected to ground by a ground wire) inembodiments that omit the LPI 312.

Referring to FIG. 31, in embodiments that include the LPI 312, the cap140 includes connectors 2034A and 2034B configured to mate with theconnectors 404A and 404B (see FIG. 28), respectively, of the LPI 312.The connectors 2034A and 2034B may be substantially identical to theconnectors 994A and 994B (see FIGS. 23B and 26). The connectors 2034Aand 2034B are positioned between the first and second channel portions2010 and 2012.

Referring to FIG. 30, by coupling the cap 140 to the injection port 116using the connectors 2034A and 2034B (see FIG. 31) and the connectors404A and 404B (see FIG. 28), the connection formed between the cap 140and the injection port 116 may withstand higher injection pressures(e.g., greater than about 30 psi) than connections formed betweenconventional caps and an injection port, which are typicallyinterference fits or detent-type connections. For example, theconnection between the cap 140 and the injection port 116 may remainedsealed and not leak when the treatment fluid 120 has been injected at apressure within a range of about 30 psi to about 1000 psi. Further, thisconnection will remain sealed and not leak at pressures below 30 psi.

The connectors 2034A and 2034B (see FIG. 31) are configured to breakbefore the connectors 404A and 404B. In this manner, the cap 140 willnot damage the LPI 312. Further, the cap 140 may absorb external forcesand help shield the LPI 312 from damage.

Referring to FIGS. 28 and 29, optionally, the cap 140 includes one ormore gripping projections 2036A and 2036B substantially identical to thegripping projections 996A and 996B (see FIG. 26). The cap 140 may begripped by the gripping projections 2036A and 2036B and twisted. Inother words, one of the gripping projections 2036A and 2036B is pushedupon at the same time the other of the gripping projections 2036A and2036B is pulled. This configuration helps overcome adhesion between thecap 140 and the MIC 100. The gripping projections 2036A and 2036B may beused to rotate the cap 140 such that the connectors 2034A and 2034B (seeFIG. 31) receive and mate with the connectors 404A and 404B (see FIG.28), respectively, when twisted in a first direction, and disengage withthe connectors 404A and 404B, respectively, when twisted in a seconddirection opposite the first direction.

In the embodiment illustrated, the gripping projections 2036A and 2036Bare positioned with respect to the connectors 2034A and 2034B (see FIG.31) to provide a visual indication of whether the cap 140 is coupled toor uncoupled from the MIC 100. In the embodiment illustrated, when thesubstantially collinear gripping projections 2036A and 2036B aresubstantially aligned with the MIC axis 340 (see FIG. 5), the cap 140 isuncoupled from the MIC 100. On the other hand, the cap 140 is coupled tothe MIC 100 when the substantially collinear gripping projections 2036Aand 2036B are substantially orthogonal to the MIC axis 340 (see FIG. 5).

Referring to FIG. 1A, the cap 140 does not have a pulling eyelet (likeeither of the pulling eyelets 258 and 260) that can be mistaken for thepulling eyelet 258 of the cap 257 or the pulling eyelet 260 of the cableaccessory 112. Thus, the cap 140 will not be mistakenly removed by alineman who is unfamiliar with injection components. This improvessafety because removing a conventional cap that is covering an injectionport alongside an energized cable has been known to cause dangerousflashovers. Further, because the cap 140 does not have a pulling eyelet,the cap 140 has a lower profile than caps that include such eyelets.

The foregoing described embodiments depict different componentscontained within, or connected with, different other components. It isto be understood that such depicted architectures are merely exemplary,and that in fact many other architectures can be implemented whichachieve the same functionality. In a conceptual sense, any arrangementof components to achieve the same functionality is effectively“associated” such that the desired functionality is achieved. Hence, anytwo components herein combined to achieve a particular functionality canbe seen as “associated with” each other such that the desiredfunctionality is achieved, irrespective of architectures or intermedialcomponents. Likewise, any two components so associated can also beviewed as being “operably connected,” or “operably coupled,” to eachother to achieve the desired functionality.

While particular embodiments of the present invention have been shownand described, it will be obvious to those skilled in the art that,based upon the teachings herein, changes and modifications may be madewithout departing from this invention and its broader aspects and,therefore, the appended claims are to encompass within their scope allsuch changes and modifications as are within the true spirit and scopeof this invention. Furthermore, it is to be understood that theinvention is solely defined by the appended claims. It will beunderstood by those within the art that, in general, terms used herein,and especially in the appended claims (e.g., bodies of the appendedclaims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that if aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to inventions containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations. In addition, evenif a specific number of an introduced claim recitation is explicitlyrecited, those skilled in the art will recognize that such recitationshould typically be interpreted to mean at least the recited number(e.g., the bare recitation of “two recitations,” without othermodifiers, typically means at least two recitations, or two or morerecitations).

Accordingly, the invention is not limited except as by the appendedclaims.

The invention claimed is:
 1. A high-pressure connector for use with acable and a cable accessory, the cable comprising a conductor, the cableaccessory having an injection port and an interior chamber, theinjection port having an opening into the interior chamber, the interiorchamber being defined by one or more sidewalls, the high-pressureconnector comprising: a body portion comprising an inner fluid chamber,an outer surface, and an aperture, the inner fluid chamber beingconfigured to allow the conductor to pass therethrough; and one or morefluid seals configured to be positioned between the outer surface of thebody portion and the one or more sidewalls of the interior chamber ofthe cable accessory to define an outer fluid chamber, the outer fluidchamber being positioned such that the opening of the injection port ispositioned within the outer fluid chamber so that a fluid exiting theinjection port through the opening enters the outer fluid chamber, theaperture being positioned to connect the outer fluid chamber with theinner fluid chamber and allow the fluid to flow between the outer andinner fluid chambers.
 2. The high-pressure connector of claim 1 for usewith the interior chamber comprising a lined portion and an unlinedportion, the lined portion being less permeable to the fluid than theunlined portion, wherein the one or more fluid seals are positionableagainst the lined portion.
 3. The high-pressure connector of claim 1,wherein the one or more fluid seals comprise first and second fluidseals each positioned on the outer surface of the body portion, thefirst and second fluid seals are configured to seal against the one ormore sidewalls of the interior chamber on opposite sides of the opening,the outer fluid chamber is defined between the first and second fluidseals, and the aperture is positioned between the first and second fluidseals.
 4. The high-pressure connector of claim 1, further comprising: afluid valve configured to be positioned within the aperture, the fluidvalve comprising a poppet member movable between an open position and aclosed position, the fluid valve allowing the fluid to flow from theouter fluid chamber into the inner fluid chamber when the poppet memberis in the open position, the fluid valve preventing the fluid fromflowing from the outer fluid chamber into the inner fluid chamber whenthe poppet member is in the closed position; and a biasing memberresting on the outer surface of the body portion, the biasing memberbiasing the poppet member toward the closed position.
 5. Thehigh-pressure connector of claim 4 for use with the injection port beingconfigured to receive an injection probe, wherein the biasing member isadjacent the opening of the injection port, the biasing member isconfigured to be pressed upon by the injection probe when the injectionprobe is received by the injection port, and the biasing membertransitions the poppet member to the open position when pressed upon bythe injection probe.
 6. The high-pressure connector of claim 5, whereinthe biasing member is adjacent to the opening of the injection port butis other than centered with respect to the opening of the injectionport.
 7. The high-pressure connector of claim 4 for use with theinjection port being configured to receive an injection probe, whereinthe fluid valve is adjacent the opening of the injection port, thepoppet member is configured to be pressed upon by the injection probewhen the injection probe is received by the injection port, and thepoppet member transitions to the open position when pressed upon by theinjection probe.
 8. The high-pressure connector of claim 4, wherein thefluid valve comprises a valve body, the poppet member is received insidethe valve body and moveable with respect thereto between the open andclosed positions, the valve body has a conically shaped inner surface,and a seal is formed between the poppet member and the inner surface ofthe valve body when the poppet member is in the closed position.
 9. Thehigh-pressure connector of claim 4, wherein the fluid valve comprises avalve body and a seal, the poppet member is received inside the valvebody and moveable with respect thereto between the open and closedpositions, the valve body has a conically shaped inner surface, and theseal is positioned to form a fluid tight seal between the poppet memberand the inner surface of the valve body when the poppet member is in theclosed position.
 10. The high-pressure connector of claim 4, wherein thebiasing member is a C-spring that is coupled to the poppet member. 11.The high-pressure connector of claim 10, wherein the C-spring isslidable along the outer surface of the body portion.
 12. Thehigh-pressure connector of claim 4, wherein the fluid valve comprises avalve body, the poppet member is received inside the valve body andmoveable with respect thereto between the open and closed positions, thevalve body has outside threads, and the aperture had inside threadsconfigured to mate with the outside threads of the valve body.
 13. Thehigh-pressure connector of claim 12, further comprising: a sealpositioned between the aperture and the valve body.
 14. Thehigh-pressure connector of claim 4, wherein the fluid valve comprises afilter configured to filter the fluid as the fluid flows through thefluid valve when the poppet member is in the open position.
 15. Thehigh-pressure connector of claim 4, wherein the fluid valve isconfigured to allow the fluid to flow therethrough and into the innerfluid chamber at between about 30 psi and about 1000 psi when the poppetmember is in the open position.
 16. The high-pressure connector of claim1 for use with the cable comprising an insulating jacket surrounding theconductor, wherein the body portion comprises first and second portions,the first portion is configured to be coupled to the insulating jacket,the inner fluid chamber allows a portion of the conductor with theinsulating jacket removed to pass therethrough from the first portion tothe second portion, and the second portion is configured to be coupledto the portion of the conductor.
 17. The high-pressure connector ofclaim 16, wherein the first portion is configured to be crimped onto theinsulating jacket, and the second portion is configured to be crimpedonto the conductor.
 18. The high-pressure connector of claim 16, whereinthe portion of the conductor has a free end received inside acompression connector, the second portion is configured to be crimpedonto the compression connector, and the first portion is configured tobe crimped onto the insulating jacket.
 19. A connector for use with acable and a cable accessory, the cable comprising a conductor, the cableaccessory having an injection port through which a fluid may be injectedinto an interior chamber, the connector comprising: a body portionconfigured to be positioned inside the interior chamber of the cableaccessory, the body portion having an aperture in fluid communicationwith an inner fluid chamber, the inner fluid chamber being configured tohouse a portion of the conductor; and first and second fluid sealspositioned on the body portion with the aperture being positionedbetween the first and second fluid seals, the first and second fluidseals being configured to define an outer fluid chamber between the bodyportion and the cable accessory inside the interior chamber, the outerfluid chamber being positioned to receive the fluid injected through theinjection port, the aperture being positioned to connect the outer fluidchamber with the inner fluid chamber and allow the fluid to flow betweenthe outer and inner fluid chambers.
 20. The connector of claim 19,wherein the first and second fluid seals are each an O-ring.
 21. Theconnector of claim 19 for use with the cable comprising an insulatingjacket surrounding the conductor, wherein the body portion comprisesfirst and second portions, the first portion is configured to be coupledto the insulating jacket, the insulating jacket has been removed fromthe portion of the conductor, the inner fluid chamber is configured toallow the portion of the conductor to pass therethrough from the firstportion to the second portion, and the second portion is configured tobe coupled to the portion of the conductor.
 22. The connector of claim19, further comprising: a fluid valve configured to be positioned withinthe aperture, the fluid valve comprising a poppet member movable betweenan open position and a closed position, the fluid valve allowing thefluid to flow from the outer fluid chamber into the inner fluid chamberwhen the poppet member is in the open position, the fluid valvepreventing the fluid from flowing from the outer fluid chamber into theinner fluid chamber when the poppet member is in the closed position;and a biasing member resting on an outer surface of the body portion,the biasing member biasing the poppet member toward the closed position.23. The connector of claim 22 for use with the injection port beingconfigured to receive an injection probe, wherein the biasing member ispositioned between the first and second fluid seals, the biasing memberis configured to be pressed upon by the injection probe when theinjection probe is received by the injection port, and the biasingmember transitions the poppet member to the open position when pressedupon by the injection probe.